The Blunt Opportunity in Pre-Rolls

Let’s talk about blunts for a minute, and not just because they’re my favorite way to smoke.

No, let’s talk about blunts because they’re not just MY favorite way and because of that, they represent a tremendous opportunity for the savvy pre-roll producer.

The pre-roll category is the fastest growing category in the cannabis industry and has been for multiple years in a row now.

On top of that, pre-rolls have been a top add-on at dispensaries across the country, as their generally inexpensive nature provide the perfect opportunity for smokers to try something new and their portability and ease of use make them a go-to for consumers.

One of the reasons for the popularity of the pre-roll is that the simple joint is still the number one way cannabis enthusiasts enjoy their weed. According to a New Frontier Data report about cannabis consumers from a few years back, even with all the new forms and trends, the average consumer’s top preference for consumption is still smoking joints, with 60% of respondents saying they roll up.

What is overlooked is that the third most popular form is the blunt, with 33% saying they smoke the joint’s larger, slower-burning cousin.

However, when we look at the sales data among pre-roll category, pre-rolled blunts make up just a small percentage of the overall market. It’s less than 1% in fact, though cannabis analytics firm Headset includes infused blunts in its “Connoisseur/Infused” category, skewing the numbers a bit and making the “blunts” segment look lighter than it actually is.

In reality, when we look at product names, the top 200 blunt products alone pulled in more than $67 million in sales so far in 2025.

But whether the infused numbers are added or not, there is only one conclusion to draw when looking at both the New Frontier consumer numbers and the Headset sales numbers: The blunt category provides tremendous opportunities for growth for producer processors looking for ways to expand their pre-roll lines and gain more market share.

What is a Blunt?

Basically, a blunt is a cannabis cigar. Traditionally, they are wrapped with a tobacco leaf. They offer a slower burn and richer, more flavorful smoke than a paper-wrapped pre-roll, as well as a little burst of nicotine from the cigar wrap.

They get their name from the “blunt” type of cigar, traditionally a cheap, machine-rolled cigar that has a single leaf outer wrapping that can be unrolled or split and then re-rolled with cannabis inside. The most famous blunts, of course, are the Phillies Blunt, though today, most traditional blunts are rolled with cigarillos.

The blunt rose to popularity in the late 1980s and 1990s, fueled by rappers from the East Coast who favored them over joints and made sure to let people know in their songs.

What is a Modern Pre-Rolled Blunt?

In the modern, legal era, the health dangers associated with nicotine and tobacco leaves have led to a rise in non-traditional wraps, like hemp or palm leaves. On top of that, every legal cannabis market bans the mixing of cannabis with tobacco products, so producers and manufacturers have also turned to non-traditional wraps to create the products we see on dispensary shelves today.

Modern, pre-rolled blunts usually use some form of hemp wrap or tea leaf wrap. Some brands still use palm leaves, though it’s difficult to find consistent sources of palm leaves that will not trip up a test for pesticides or heavy metals absorbed during the growth of the tree.

Most pre-rolled blunts today also use some sort of filter, usually paper or wood filter tips, though premium options like glass and ceramic filter tips that help further cool the smoke for bigger hits are also growing in popularity.

Pre-rolled blunts can come in tube or cone form and in multiple sizes, with some using the form to go bigger than the usual pre-roll, packing 1.5- or 2-grams into a single smoke.

How Well Do Pre-Rolled Blunts Sell?

So while blunts might be the third-most popular form for smokers, the fact is they don’t make up a very large percentage of the cannabis market share, even within the pre-roll category.

In fact, of the seven segments of pre-roll tracked by Headset, the “Cannagar/Blunt” category comes in sixth place, above only CBD pre-rolls. Of the $2.2 billion in revenue generated by pre-rolls in the first eight months of 2025, only $11.4 million came from blunts.

Again though, that data does not include all of the infused blunt products on the market, which are inexplicably split between the blunt and infused segments for reporting purposes.

However, a pull of the Top 200 products that feature the word “blunt” in their name totals sales of $67,047,817 on 3,494,703 units sold, just among those 200 products.

That shows there is not only a wide national customer base interested in pre-rolled blunt products, but still an opportunity for brands to make their mark and corner the market in their state(s) on these products.

What Options are There for Pre-Rolled Blunts?

Producers looking to add or expand a pre-rolled blunt line must first choose exactly what their pre-rolled blunts will look like, which will then lead to the available options on wrap type and filter tip options.

Like pre-rolled joints, pre-rolled blunts come in either cone or tube form. Cones tend to have classic, “w”-style paper filters and will fit in cone-filling machines, making it an easy transition from joints to blunts during production. Tubes, on the other hand, come in larger sizes and have additional premium filter tip options like wood, flavored wood, glass and ceramic, but may require a tube conversion kit and additional parts to fill using standard pre-roll machines.

After choosing size and shape, the next decision is wrap type. The most common choice is hemp wrap, but tea leaf wraps, palm wraps and other botanical wraps, such as goji berry, are also popular.

Custom Cones USA also offers a hybrid hemp wrap option that burns and smokes like a traditional hemp wrap, but is less sensitive to moisture because of its unique formulation so it will last longer without cracking.

What are Custom Cones USA’s Pre-Rolled Blunt Choices?

Custom Cones offers a wide range of pre-rolled blunt options, including both pre-rolled cones and pre-rolled tubes in a variety of sizes and wrap options.

Let’s start with the pre-rolled blunt cones.

Pre-Rolled Blunt Cones

Custom Cones USA carries brown hemp wrap pre-rolled blunt cones, made with all-natural European-sourced hemp, in standard sizes such as 84mm (half-gram), 98mm (¾-gram) and 109mm (full gram), all with a 26mm traditional paper “w” filter tip that is 9mm in diameter.

The natural brown hemp provides the look and feel that traditional blunt smokers love and expect, but the industry-standard sizing means these hemp pre-rolled blunt cones fit in standard pre-roll cone filling machines.

These same cones are also available in hybrid hemp, which uses a different mix of fibers and other hemp material to create a more pliable, less moisture sensitive hemp wrap that still burns slowly and has the same flavor profile as traditional hemp wraps.

The hybrid hemp wrap blunt cones are also available in 84mm, 98mm and 109mm. They come in brown, dark brown and a unique green. There is also a 109mm (full gram) pink hybrid hemp cone, for companies looking to truly stand out on dispensary shelves.

There are also 109mm botanical blunt wrap cones. The tea leaf cones, made with chamomile and traces of cocoa and vanilla have a light, sweet flavor and are very much like Futurola’s pre-rolled blunt cones. There are also bright, pink 109mm goji berry cones, that have a subtle berry flavor that compliments the flower without overpowering it.

For producers wanting to offer a more premium pre-roll experience, there are options with both wood and glass filter tips that at 11mm in diameter, including 109mm (1.5-gram) and 90mm (full gram), available in both standard and hybrid hemp wrap options.

Both the wood and glass filters come standard with dual paper spiral filter built right in to better block particles and resin, while cooling the smoke for bigger hits.

Pre-Rolled Blunt Tubes

Moving to the pre-rolled blunt tubes, the options expand even further, particularly when it comes to filter tip options. However, all of the pre rolled blunt tubes that Custom Cones USA carries are 109mm in length and 11mm in diameter and will hold about 2 grams of flower.

The simplest filter on the 2-gram 109mm pre-rolled blunt tubes is the paper spiral. Built into the tube, with the hemp wrap stretching all the way to the bottom, the paper spiral is designed to not only keep out “Scooby Snacks” and particles, but to also collect sticky resin before it hits the customer’s lips. They come in standard and hybrid hemp wrap varieties as well as in a tea leaf pre-rolled tube and have the most traditional blunt feel to them, because of the way the wrap sits on the lips.

There is even a tea leaf blunt tube version with the spiral filter tip.

When it comes to a wood filter tip, Custom Cones USA has multiple varieties. First, there is a standard flat-mouth wood filter tip that fits easily between the lips and feels like a classic cigarette holder. There are even flavor-infused wood tips in both sweetened and vanilla, that add a nice taste to the lips while never getting in the way of the flower you load into them.

Next up are the cylindrical wood filter tips. These beauties have the same natural feel on the lips as the flat-mouth filters, but like the spirals, their roundness allows for a wider opening for the smoke, leading to bigger hits. But fear not, they also have a dual paper spiral filter inside to help block particles and resin.

Moving to glass filter tips for blunt tubes, there are two choices: Cylindrical and bullet glass. The cylindrical glass filters are more traditional of glass filter tips and leave more of the glass showing, including the part that sits on the lips. The weight and smooth, classic feel of glass truly give these pre-rolled blunt tubes a premium feel, while the natural properties of glass help cool the smoke even further than wood or paper. Along with standard and hybrid hemp, there is even a tea leaf version of these as well.

The embedded bullet glass filter tip blunt tubes take things to the next level, bringing the best aspects of both the dual glass filter – blocking particles and cooling the smoke, while the embedded nature of the filters allows for the natural feel of the hemp wrap on the lips. It’s a best-of-both-worlds kind of product that your customers are going to love.

Finally, there are ceramic filter tips options, the height of pre-roll luxury. No filter tip material cools the smoke better than ceramic, due to the natural heat-trapping and distributing properties of ceramic. Custom Cones USA carries ceramic filter tipped blunts in both a flat mouth and cylindrical options.

Custom Cones USA also sells silicone blunt caps, a fast and easy way to close your filled pre-roll blunts without having to fold the hemp.

And all pre-rolled blunt cones and pre-rolled blunt tubes can be customized with cigar bands to make sure your branding and messaging always comes through.

Final Thoughts on Pre-Rolled Blunts Opportunities for Brands

While the numbers for the pre-rolled blunt category may seem small in comparison to the size and scope of the pre-roll market as a whole, blunts are still a $67 million-plus segment of the market, when you include both traditional flower-only and infused pre-rolled blunts.

On top of that, blunts remain the third-most preferred method among average consumers.

Put those together and the pre-rolled blunt market is simply waiting for the right brand and primed to explode. Smart pre-roll producers will see this as a mostly unexplored, Blue Ocean-style market and adapt their pre-roll production lines to jump in and make their products the cornerstone of a growing sub-category.

Pre-rolled blunt cones make an easy switch in standard pre-roll filling machines, making them an easy choice to test a new market, while pre-rolled blunt tubes provide a wide range of premium filter tip options that truly help products stand out.

The only limit is your imagination. Contact the Pre-Roll Experts today to see how Custom Cones USA can help your company become a leader in the pre-rolled blunt segment.