Pre-Roll Master Class: Part I – Rolling Paper Science

Making consistent, high quality pre-rolls at scale is not just a business, it’s a craft. There is an art to it.

But that doesn’t mean there aren’t some fundamentals, as well as tips and tricks, that can make it easier.

At Custom Cones USA, we are the Pre-Roll Experts. We’ve spent years studying what goes into making perfect pre-rolls and our mission is to revolutionize and enhance pre-roll products by setting a benchmark for excellence and innovation in the industry.

We’ve designed this course to help you get a better understanding of exactly what it takes to make, package and sell a high-quality pre-roll. From the paper science to best practices on grinding and packing machinery that can help that process to the latest trends like infusing pre-rolls with a concentrate or packaging types, as well as a look at some of the common testing and packaging regulations from the various state markets around the country, we’ll cover it all.

There’s a lot here, but by the end, you’ll have all the basics and understanding you need create a top-of-the-line pre-roll brand. So let’s get into it.

What is a Pre-Roll?

Let’s start with the basics: What is a pre-roll?

A pre-roll is a cannabis cigarette, or joint, that has been prepared ahead of time, usually containing a filter or crutch at the mouth end.

Pre-rolls are a multi-billion dollar per year sub-category and have become a staple and a symbol of the modern cannabis industry, as well as the number 1 add-on at dispensaries across the country. They are the fastest-growing cannabis product category over the past 2 years, with nearly 12% growth across all of the U.S. markets tracked by Headset, a cannabis analytics firm out of Seattle, WA that uses point-of-sales data.

Customers love the ease and portability of pre-rolls and because of it, the product has a market share of about 15% across the cannabis industry. They are an easy and relatively discreet way to sample different strains or just take a moment for yourself.

And for producers, they are a familiar product that also offers a broad canvas for innovation. That has led to the increased popularity of infused pre-rolls, which combine flower with a cannabis concentrate, increasing potency and flavor.

Pre-Rolls come in a wide range of sizes, from personal mini cones that only hold about 0.3-grams (often called “dogwalker” cones) to giant size party cones that can hold multiple grams of flower.

However, the two most common sizes are the 109mm full-gram king size cone and the 84mm half-gram size, sometimes called 1 ¼ size and often used in multipacks, including the very popular 2.5 gram 5-pack. And while the 1-gram package is the most popular size (just under 50% of sales), they are often two half-gram cones in a multi-pack, making the 84mm the most popular size cone.

The most popular shape for pre-rolls is the traditional cone, which tapers from the packing end to a paper filter at the mouth end that helps cool the smoke and catch any particles from being pulled through. The standard for filters is a length of 26mm – though 21mm are popular as well – and the most common shape is the “w” shape, though there are a ton of premium options available from paper spirals to natural and flavored wood, premium glass and high-end ceramic.

Pre-Roll Rolling Paper Options

The first place to start on any discussion of pre-rolls is the rolling paper, which forms the foundation of any pre-rolled cone. And the best rolling paper mills in the world are in Europe, where they invented the product.

There are a handful of common pre-roll paper types in the industry. We refer to them as Refined White, Natural Brown and Organic Hemp paper.

Refined White

Let’s start with the refined white paper, as it is the most common. You may hear the term “rice paper” from time to time, but it’s a bit of an anachronism at this point. Rolling papers are not made from rice, of course. They are made from wood, like any other paper. Traditionally, “rice paper” refers to paper that is white in color, as well as the thinness of the paper. But in the modern industry, it’s a misnomer that can confuse customers.

These are also the most transparent papers and cones, which make them great for creating pre-rolls that have something printed on the filter.

The truth is that the white color and delicate nature of rolling papers comes from the refining process, which removes a substance called “lignin” that, in part, helps give wood its brown color. The more refined the wood that makes the paper, the whiter and thinner your cone.

You may also hear the term “unbleached,” but like “rice paper,” “unbleached” white rolling paper is another misnomer and more marketing language. If your rolling papers or cones are white, they have been through a "bleaching" process, which in papermaking just means the whitening process, but doesn't necessarily mean chemical bleach was used.

You could have bleached paper that is whitened with no harsh chemicals or bleached paper that is whitened using chlorine and other harmful chemicals, so the word "bleached" isn't a bad thing. But the method of bleaching can be and is super important to look into.

There are four steps to preparing the wood fibers for the paper-making process: delignification, washing, bleaching and drying.

Again, in this case, “bleaching” is a generic term for whitening, which is done in one of two primary ways: Elemental Chlorine Free (ECF) and Total Chlorine Free (TCF). The ECF process uses chlorine dioxide, the TCF process uses oxygen, hydrogen peroxide, or ozone, sometimes in combination.

Chlorine, as you know, is the main agent used in home bleaches, like Chlorox. It is also a very nasty chemical that is dangerous when inhaled, which means combusting and smoking it is always a bad idea. Custom Cones USA never use any chlorine bleaches.

At Custom Cones USA, we use a Total Chlorine Free process with hydrogen peroxide as the bleaching agent.

That’s why we go with “Refined White.” It’s a more straightforward term that better suits a modern, transparent industry.

Natural Brown

But not every customer is attracted to the refined white cones. Some like their papers a little less refined and a little more natural looking. We use the term “Natural Brown” to describe these papers. They are made in the same way as the white papers, but they are refined for a shorter amount of time and retain more lignin, which is why they have a brownish quality to them. They are still nearly transparent, but simply not white.

Again, whereas other companies may use more colorful terms for less refined papers, we go with “Natural Brown.”

Hemp Paper

As for hemp paper, it’s just made with hemp fiber instead of wood. For some brands, especially those with an ecological bend, wrapping their pre-rolls in hemp is an appealing marketing decision, particularly if the hemp is organically and sustainably sourced, as we do at Custom Cones USA.

Some people also find that hemp paper has an earthier flavor than the flavor-free refined white or natural brown cones and enjoy the way it complements the flower. As you can see, the hemp paper cones also have a slightly tan tone to them, but are mostly transparent.

How to Measure Rolling Papers

Rolling papers are ultra-refined to be incredibly thin and nearly transparent. They are some of the finest papers made.

Paper is classified by a measurement called “GSM,” or grams per square meter. It is based on the paper’s weight. Generally speaking, the heavier the paper, the higher the number of grams per square meter. Usually, a higher number indicates a higher quality paper.

For example, standard printer paper runs about 90-100 gsm, while a magazine cover is usually between 200 and 300 gsm. Business cards and greeting cards run about 300 to 400 gsm.

However, in the world of rolling paper, the smaller the number the better since a higher gsm means the consumer is smoking more paper. Cigarette paper, for example, is about 28 gsm.

So how thin is thin? Our ultra-refined white and natural brown rolling papers each have a gsm of just 12.5, while our organic hemp papers have a gsm of 13.5. And that makes for a much nicer smoke.

Pre-Rolled Hemp Wrap Blunt Cones

Another popular form of pre-rolled cone is the hemp wrap cone, which is the industry’s version of a blunt, or cannabis cigar.

Blunts are traditionally wrapped in cigar leaves, but because of the industry-wide prohibition on using tobacco products, the hemp wrap – a thicker, slower-burning hemp paper made at about 60 GSM – is the main choice for pre-rolled blunt cones. It has an earthier flavor than more refined paper options.

However, hemp cones have a tendency to lose moisture over time and can become dry and crumbly without storage in a humidor or with moisture packs, which is why we developed our Hybrid Hemp Wrap Cones, made with a combination of hemp fibers, other plant materials and natural additives that retains the flavor and smokeability of traditional hemp wraps without being as susceptible to the elements. They have a gsm of 50.

Final Thoughts - The Importance of Rolling Paper Testing

One other note about rolling papers before we move on; Like any other plant, including cannabis, trees absorb heavy metals through the soil that make their way through the entire refining process. They can also harbor dangerous microbials or residual pesticides.

In fact, there have been multiple studies, including by California’s SC Labs and academic researchers in Michigan, finding high levels of heavy metals, pesticides or microbials in rolling papers.

But while flower is required to be tested for dangerous levels of contaminants, rolling papers are not. And there have been several product recalls throughout the industry due to batches of pre-rolls that have failed tests, presumably due to the paper.

It’s important to make sure any rolling papers or cones used for the manufacture of pre-rolls be tested to the same high standards as the industry itself and all pre-roll businesses should ensure their supplier has Certificates of Analysis on hand for their cones.

Next, in Part II, we’ll look at the Importance of Grinding and Sifting.