Pre-rolls aren’t just another SKU on the menu anymore. They’re one of the top-selling categories across dispensaries nationwide, and the bar for quality keeps rising. The pre-roll category makes up about 15–16% of U.S. cannabis sales, with infused pre-roll products now accounting for ~44% of the segment, one of the fastest growing categories nationwide. The bar for quality keeps rising.
At one end, budget eighths are packed into cones for affordability. At the other, luxury infused joints with live resin or rosin are gaining traction across multiple markets.
With choices expanding at both price points, the pre-roll space is more competitive than ever. The companies that win will be the ones that build automation into their operations, combining scale with consistency and quality.
Budget eighths are frequently packed into cones, luxury infused joints with live resin or rosin now exist in numerous markets, the space is as competitive as ever.
The brands making real moves right now are the ones investing in superior machinery resulting in better finishing techniques, consistently produced products providing a smoother and more enjoyable smoke, and details that elevate the consumer experience.
At the center of that evolution is Hefestus, a company that’s taken pre-roll automation from a convenience tool into a quality-driving necessity. One of the most important elements they’ve brought to the table is the Dutch Crown joint fold. It may not have the flash of newer pre-roll trends, but it is an essential feature that protects airflow, prevents loose ends, and ultimately increases the enjoyment of the pre-roll.
Scaling Pre-Roll Production Without Sacrificing Quality
Anyone who’s rolled joints by hand knows the process is labor-intensive, inconsistent, and nearly impossible to precisely scale.
For small craft teams it works, but once you’re producing tens of thousands of units for dispensary shelves, the problems quickly become apparent:
- Uneven weights that break compliance and hurt customer trust.
- Canoeing burns that frustrate consumers and waste product.
- Clogged machines when sticky flower or infused material gums up production.
- Sloppy and subpar packaging that make a premium brand look cheap.
Hefestus stepped into that chaos with their Aura series of machines. These Aura pre-roll machines were built to handle both full-flower and infused joint material across all sku types: full sized cones, cigarette-style tubes, dog walkers and blunts.
Instead of treating automation as a shortcut, their approach has been to engineer solutions that improve the smoking experience as much as the production line.
The Dutch Crown: A Small Detail With Big Impact
The tip of a joint sets the tone. Twist-tops are common, but they come with problems. They’re harder to light, they can trap air in awkward ways, and they often create uneven burn paths.
Consumers may not analyze it in detail, but they know when a joint doesn’t hit right.
That’s why the Dutch Crown fold has become a mark of craftsmanship.
By folding the paper flat at the top, you get:
- Cleaner ignition — easier to light, no struggle torching through twisted paper.
- Even airflow — reducing canoeing and helping the joint burn consistently.
- Premium look — the finish signals quality before the first puff.
It’s like plating in fine dining: presentation primes the experience.
A Dutch Crown looks better, smokes better, and Hefestus automation delivers that consistency across thousands of joints per day.
Simplicity and consistency at scale is absolutely key to maintaining efficiency.
Full-Flower Pre-Rolls: Consistency Is Everything
With full-flower joints, the typical challenges involve density and distribution. If the cone is packed too loose, it burns too fast. Too tight, and the draw gets harsh. Even with good material, bad packing can ruin the smoke.
Hefestus machines are engineered for manufacturers to be able to customize their joints by controlling the fill density, ensuring every joint comes off the line uniform. Pair that with a Dutch Crown fold and you’ve got a product that lights clean, burns even, and smokes like it was rolled with intention.
For brands trying to build loyalty, that consistency is priceless. Consumers who buy one pre-roll and have a great experience are way more likely to grab a multipack, or more than one strain at a time.
Infused Joints: Precision on Another Level
Infused pre-rolls are where things get really technical. Adding concentrates such as live resin, rosin, distillate, or kief changes everything about how the joint handles and burns.
Sticky flower frequently clog infererio -pre-roll automation machines.
Uneven infusion creates hot spots that burn unpredictably.
And because infused joints carry higher price tags, the tolerance for error at the customer level is slim to none. You just can’t mess up when joints cost good money.
Hefestus engineered its machines to handle sticky, resin-heavy material and keep production moving. Drawing on decades of experience solving sticky challenges in food and other automation lines, the team built solutions to pain points long before pre-rolls demanded them. Paired with automated Dutch Crown folding, this allows brands to deliver infused joints that look polished and burn smooth, no matter how complex the recipe inside.
When customers are paying twenty dollars for a single infused joint, these details define the top shelf and separate it from the bargain bin.
The Competitive Edge in Presentation
A Dutch Crown finish sets a joint apart. It signals care, consistency, and professionalism, elevating the product into the premium tier.
Budtenders lean on it as a clear talking point when guiding customers.
Consumers recognize it as a mark of something special. And when you line it up against budget multipacks, mid-tier rolls, and infused options, it’s the detail that catches the eye on the dispensary shelf.
Hefestus as a Partner in Innovation
Hefestus has been in automation for over three decades and in the cannabis industry & pre-roll automation for over a decade. Although they aren’t the only player in pre-roll automation, their ability to combine technical reliability with aesthetic quality has made them stand out.
Machines that weigh, pack, and fold consistently save operators money and build brand equity. By taking details like the Dutch Crown fold seriously, Hefestus shows they understand cannabis is about efficiency and experience together.
Pre-rolls live or die by how they smoke, and the companies investing in that experience are the ones setting themselves up to win.
The pre-roll game has evolved — no question about it.
Consumers expect joints that light smooth, burn evenly, and feel premium, especially when infused concentrates are involved.
Hefestus has positioned itself at the heart of that shift, offering machinery that keeps production moving while elevating the final product with features like the Dutch Crown fold.
For operators, automation must respect the plant, the process, and the people lighting up on the other side. That means not only honoring the flower itself but also maximizing all of its components—cannabinoids, terpenes, flavor, and aroma—so consumers experience its full potential.
Visit Hefestus-Tech.com for more information.
