Pre-Roll Master Class: Part V – Pre-Roll Packaging and Testing Considerations

Welcome back to Part V, the final installment of the Custom Cones USA Pre-Roll Expert Master Class where we are covering the fundamentals, as well as tips and tricks, of creating high-quality pre-rolls at scale.

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 by sharing that knowledge.

In Part I, we covered Paper Science 101, looking at the basics and science of what goes into making the rolling papers that make pre-rolled cones.

In Part II, we covered the Importance of Proper Grinding and Sifting.

In Part III, we looked at some of the Best Practices for Pre-Roll Manufacturing, including Pre-Roll Filling Machines

In Part IV, we got into the Pre-Roll Infusion and Automation Options.

In this final part of our series, we’re going to cover the final steps of the process.

These final steps in the pre-roll production process are also the ones that have the strictest rules and regulations that govern them: packaging and testing.

Pre-Roll Packaging Considerations

No matter how good the pre-rolls inside are, the first thing your customers are going to see is your packaging, so make sure you choose the one that best aligns with your brand’s message.

Are you a high-end, top shelf brand? Look toward a high-end material, like glass, so customers know what to expect. A budget brand? Can’t go wrong with a plastic pop top doob tube. Pride yourself on an artisan or eco-friendly message? Let shoppers know with paper, reclaimed ocean plastic or other environmentally friendly materials.

As long as you are sure to read and conform to your state’s packaging laws, the possibilities for your pre-roll packaging are nearly limitless.

The Doob Tube

The most common form of pre-roll packaging is, of course, the plastic pop top tube. Known as the “doob tube” and available in multiple colors and sizes, these tubes can be fully customized with labels to provide not only branding and product info, but also any warnings or information required by regulations. They are also certified child-resistant.

Along with the classic doob tube, glass tubes are very popular for single pre-rolls or pre-rolled blunts and signify to consumers a more upscale product. Glass tubes also let you show off your pre-rolls so customers can see what they’re getting before they buy. They’re great for designer or custom crutches, as well as blunts, externally infused pre-rolls and other eye-catching products.

Clear plastic tubes that look like glass are a great, cost-effective alternative to glass. They highlight the product in the same way and still register among shoppers as a more premium product, but won’t cost you as much up front.

The Multi-Pack Boom

But the biggest trend in cannabis packaging is the multi-pack, which combines several pre-rolls into a single piece of packaging. Producers love them because they cut down on labor, materials and costs, while customers flock to them because it prevents them from having to go back to the dispensary over and over, as well as the lower “bulk” price point.

In fact, according to the data, multi-pack sales accounted for nearly 50% of the pre-roll market in June 2024, up from just 27.7% in 2018. Multi-pack revenue has also climbed, going from $89.1 million in January 2023 to $127.4 million in June 2024, a 43% increase in just 18 months.

The most popular size multipack is the 2.5-gram 5-pack, which made up 31 of the top 50 best-selling pre-roll products from January 2023 through June 2024.

There are a variety of packaging options for multipacks, from wide-mouth pop-top doob tubes to flip top or slider tins to paper boxes and everything in between (including dividers, if you want them!), so there’s always something that works for every brand. And all are customizable to make sure your brand and brand message always come through.

Eco-Friendly Pre-Roll Packaging

Another trend in pre-roll packaging is a move toward more eco-friendly packaging. For companies looking for a greener alternative to the standard plastic doob tube while keeping a similar look, there are tubes made of reclaimed ocean plastic, hemp plastic post-consumer recycled plastic, aluminum and even paper.

Some states, like Vermont and New York, have packaging regulations requiring more eco-friendly options. In Vermont, for example, plastic is not allowed for cannabis packaging (except as part of the child resistance mechanism), while in New York’s market, all plastic used for cannabis packaging must be made of at least 25% post-consumer recycled plastic.

Pre-Roll Packaging Regulations

Because cannabis is still federally illegal, each state is essentially its own unique industry. And each state has its own regulations surrounding cannabis packaging, so it’s important to understand your local laws and the rules that govern the industry in your state.

But that said, there are a few common rules worth going over, most of which deal with safety concerns.

Child-Resistant Pre-Roll Packaging

Almost every state, for example, requires pre rolls to be sold in certified child-resistant packaging. Some even require the packaging to remain child resistant after it has been opened and re-closed.

The history of child-resistant packaging goes back to 1967, when Dr. Henri Breault invented the child-resistant locking closure for containers. A few years later, Congress passed the Poison Prevention Packaging Act of 1970, giving the U.S. Consumer Product Safety Commission the authority to regulate consumer packaging. Today, almost all U.S. cannabis laws reference the PPPA as a foundation for state packaging regulations.

The mechanism changes with each package design, of course, but the most common motions are “Push Down & Turn” and “Squeeze Lock” closures. The Push Down & Turn is like those used on pill pottles and requires extra force before the cap to be opened, often found on jars. The Squeeze Lock type of closure usually consists of a lid that is squeezed on both sides to release the lid from a set of tabs or its nested position and is often associated with the standard “doob tube.”

There are other, two-button or squeeze methods for tins and push-and-slide style openings for push packs and slider boxes that require two intentional steps to prevent small hands from accidentally or intentionally popping open a pre-roll.

Child resistance is certified by independent companies, based on the “Code of Federal Regulations,” or CFR Title 16, Part 1700 that reaches back to the 1970 law or ASTM’s Standard Classification of Child-Resistant Packages.

Again, requirements vary from state to state, but if your market requires child resistant packaging, make sure any supplier you use has the paperwork to prove their packaging meets standards.

Opacity in Pre-Roll Packaging

Another thing to watch for in your state’s regulations is opacity. Some states require cannabis packaging, including pre-rolls to be opaque, so you can’t see the product inside. Again, if this is a rule in your market, make sure your pre-rolls are packed in dark containers, no matter if you choose plastic tubes or more premium glass tubes.

But even in states where you have a choice, opaque vs clear or transparent is an important packaging consideration for multiple other reasons.

For example, for marketing purposes, it makes sense to package high-quality or unique-looking products, such as pre-roll blunts, infused pre-rolls or pre-rolls featuring premium filter tips in transparent containers so customers can see what they are getting and encourage them to buy.

However, at the same time, it is important to note that with a clear tube, light degradation can also be an issue as exposure to UV rays – such as those through a clear, glass tube – can also affect the product and cause a drop in THC percentage, converting it to CBN.

This may not be a problem if your products are flying off the shelves, but it is something for manufacturers to consider when choosing packaging. In a similar vein, moisture getting into or out of your packaging can cause problems for a pre-roll as well, either creating conditions for mold or drying out your flower, which is why many producers opt for airtight packaging, or add even a small humidity pack in with their product.

Tamper-Evident Requirements

Another common requirement is a tamper-evident band to alert consumers to the fact that a product has been opened. This can be achieved in a many ways.

Some brands opt for strategically placed stickers or neck bands to create tamper-evident packaging. Others use a small, shrink-wrapped plastic band around the top. Some companies choose to deal with branding and tamper evidence in one go through custom-designed shrink sleeves or other creative label solutions that are applied to packaging.

Still others reach for products like Super Seal tubes, which are a little more expensive than a simple plastic pop-top, but are child resistant, tamper evident and airtight.

When the cap is sealed during production, it simultaneously creates an airtight, tamper-evident seal that is also child-resistant after opening. It's a premium choice for premium pre-rolls and customers can feel the difference.

Pre-Roll Labeling

Finally, let’s talk about a few common labeling considerations. Again, your local market may have specific rules surrounding packaging, so make sure to check with local regulators, but there are a few common themes to watch for, both in what they require and in what is not allowed.

As for requirements, packaging labels often must include testing information as well as batch information from the flower producer and manufacturer. Many states also require specific warnings, including symbols that are often particular to individual states, be they a cannabis leaf or a “21+” note or the letters “THC.” Some states, like Missouri, go even farther, which is why Custom Cones USA makes pre-rolled cones with Missouri’s state-specific warning symbol printed right on the filter itself.

Again, consult your local laws for specifics.

For labels, the main consideration is to not appeal to children. That means less focus on bubble letters or cartoons. It often means bright colors and product names that resemble or parody popular candy brands are frowned upon. This is usually a bigger issue in the world of edibles, but pre-roll manufacturers also need to be aware that anything that looks too appealing to children will probably not fly with regulators.

Final Thoughts on Pre-Rolls

This concludes our Pre-Roll Expert Master Class.

From the paper science, to the importance of grinding and sifting and pre-roll manufacturing best practices, as well as a look at how to make infused pre-rolls and the packaging decisions and regulations you need to consider, you now have all the basics you need to get out there and build a pre-roll production line.

But remember: what you do with that knowledge is up to you. The pre-roll is a versatile and highly innovative product form that is familiar to consumers and only growing in popularity as more and more markets open, so the limit truly is your imagination.

Also, while everything in this class is important information, it is just a jumping-off point. For more information on any subject in this course, please visit the Pre-Roll Expert Blog on the Custom Cones USA website or contact the Pre-Roll Experts today.

One more note: Remember to fully vet your pre-roll supplier to make sure that they are a partner with your company’s best interests in mind and that they test their products to the strictest standards in the industry and have the certifications and certificates of analysis to keep you on the right side of regulators in your state.

Now, let’s get packing!