“This is how you make great splices” – How one machine produces 900 pre-rolls an hour and why they’re better than cones

“My first legal joint burned like hell. It was hot, the material dried, and then it was canoeing,” recalls Kyle Laux, Founder and CEO rolling pro, He describes his experience working in the cannabis pre-roll space. For Laux, that moment was more than a personal disappointment, it brought a momentous realization. What was supposed to be a magical milestone celebrating legalization and quality craftsmanship ended up being met with a product that fell well short of expectations. Rather than move on, Laux decided to do something.

Front patch issues: an expert’s perspective

Laux’s first pre-volume is a celebration of how far the industry has come. Instead, it exposed a long-standing problem in the market. “I saw a problem,” he said. “It’s not my level of joint.” For a man who has spent more than 20 years perfecting the art of hand-rolling, encountering such a shoddy product sparked an idea. Back in his garage, Loucks began researching a solution that would provide consistent, high-quality joints at scale.

At the heart of his solution is TruRoll technology, a proprietary system that revolutionizes the traditional cone filling process. “We feed it horizontally so you can fill it with fresh, sticky weed with a large grind size. Then we roll it and tighten it up. It’s a better way to connect,” explains Laux.

The horizontal feed method solves a common challenge with cones: narrow apertures, which often lead to uneven packaging and airflow issues. By rethinking the rolling mechanism, Loucks developed a system that preserved the integrity of the flowers while ensuring a consistent burn. His invention appealed not only to artisanal growers but also to larger operators looking for efficiency without sacrificing quality.

Process meets automation

RollPros’ flagship product, the Blackbird rolling system, is designed for cannabis enthusiasts who value precision and consistency. It combines Loucks’ practical experience with advanced automation to replicate the quality of hand-rolled joints on an industrial scale. “We have now completed over 80 million joints and have approximately 160 machines,” Loucks shared, highlighting the growing demand for his technology.

Blackbird’s design focuses on preserving the uniqueness of the joints. “I selfishly designed it for myself,” Laux said, emphasizing his personal standards as a cannabis connoisseur, valuing flowers and optimal burning qualities. “I like a large grind size to preserve all the flavonoids and terpenes in the plant,” he adds. To complement this, RollPros sources high-quality paper from one of France’s oldest paper mills, ensuring even, smooth burning.

In addition to quality, Blackbird also focuses on flexibility. Operators can customize nearly every aspect of the rolling process, from density and stretch resistance to the type of filter or paper used. “You can do big fat tips, small nails, ceramic tips, glass tips, wooden tips — it’s all customizable,” Laux explains. The machine’s adaptability enables brands to customize products to meet customers’ specific preferences, creating a unique image in a highly competitive market.

Meeting the needs of artisan growers and others

For Loucks, the design of the Blackbird Rolling System has always been rooted in serving the craft cannabis community, which values ​​quality and freshness over mass production. “It’s really tailor-made for artisanal growers,” he explains. Inspired by the dedication of phenomenal hunters and small-scale growers in places like the Emerald Triangle, Laux wanted to create a tool that could be seamlessly integrated into these operations while maintaining the standard of hand-rolled joints.

The Blackbird’s compact size makes it ideal for this type of setup. It measures about four feet by two feet and stands about four feet tall, no larger than two college refrigerators placed side by side. “It has casters, so you can roll it from room to room,” Laux added.

However, the practicality of the machine does not stop at the process level. Blackbird is also receiving attention from larger players in the cannabis industry, including multi-state operators (MSOs) looking for efficient and scalable solutions. “Large MSOs have been using our equipment,” Loucks shared. “It’s great to see big companies starting to look at us and say, ‘This is how you build a great consumer experience.'”

Investment and ROI Equations

Of course, innovation comes at a cost. The Blackbird rolling system is an investment, with a starting cost of approximately $250,000. This may seem like a steep entry point for some operators, but Laux points out that the machine’s scalability and potential for large outputs can make it a cost-effective option in the long run. Capable of producing approximately 900 joints per hour, the system can quickly pay for itself in the right hands.

Laux tells the story of a resourceful customer who purchased Blackbird and turned it into a mobile rolling service. “He would load it up in a trailer and roll it out onto the farm and provide a rolling service. Then he would load it back up and go to the next location,” Laux explained. This entrepreneurial approach not only provides immediate value to local growers, but also enables customers to recoup their investment faster than expected.

For operators who may not have the upfront capital, RollPros offers leasing options to make the technology more accessible. This flexibility ensures that artisanal growers and boutique operations can still benefit from Blackbird’s capabilities without being priced out of the market.

Beyond the Roll: The Future of Cannabis Innovation

While Blackbird Rolling System has already carved out a niche in the cannabis pre-roll market, Loucks is already looking ahead to the next set of challenges facing the industry. “I think packaging is next,” he said, noting that sustainability is a key area for improvement. Current pre-roll packaging options often rely on single-use plastic or other environmentally unfriendly materials, a problem Loucks believes can be solved through the same innovative thinking that brings TruRoll technology to life. “I wanted to find some more sustainable packaging options, but I had to do it with the same level of innovation as Blackbird.”

Laux’s approach to problem-solving is rooted in collaboration. “I love brainstorming ideas,” he shared. “Connect with me on LinkedIn, we’ll do Zoom, I’ll pull out the whiteboard — tell me your problem.” For Laux, innovation doesn’t happen in isolation. By inviting growers, operators and other industry professionals to share their pain points, his goal is to create solutions that are not only technically sound but deeply aligned with the needs of the cannabis community.

Making rituals one joint at a time

Despite Blackbird’s technological advancement, Laux quickly realized the value of humanity in cannabis culture was irreplaceable. For many enthusiasts, rolling a joint is as much a ritual as it is an end product. Laux, a self-described “ritual master,” understands this. “Rolling a joint is like making espresso,” he said. “It’s about the smell, the feel, the whole experience.”

This perspective is built into the fabric of RollPros. While Blackbird enables consistent, high-quality mass production, it does not seek to replace the hand-rolling process. Rather, it provides a tool for those who want to take their craft to the next level, blending tradition with innovation. “The people who have really had success with our machines are United Rollers and United Smokers,” Laux explained. “They know what a good joint looks like, and they can dial in the machine to hit all of those same parameters.”

A growing legacy

With over 80 million cannabis pre-rolls produced and a growing customer base ranging from boutique craft growers to large MSOs, RollPros is becoming a cornerstone of the cannabis pre-roll industry. Laux attributes much of this success to his ability to stay connected to the communities he serves. Whether it’s through brainstorming sessions, hands-on product development, or simply sharing his passion for rolling a joint, Loucks shines a spotlight on the people who make the cannabis industry what it is today.

As Laux looks back on his journey, he remains energized about the challenges ahead. “There are big problems across the industry,” he said. “I’m here to help solve these problems.”

Image courtesy of RollPros.