The Blunt Boardroom

How Pre-Rolls Are Made at Scale | The Blunt Boardroom Ep. 05 Ft. Jonathan McFarlane & Maddie Bailey

Season 1 Episode 5

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0:00 | 1:00:22

In this episode, Matt sits down with Jonathan McFarlane, Chief Marketing Officer of RollPros, and Maddie Bailey, mello's post-production supervisor and the person responsible for every pre-roll that comes off the Blackbird. Together they get into what it actually takes to produce award-winning pre-rolls at commercial scale, consistently, and at a cost per unit that makes the business work.

Maddie came to mello from a car dealership. No pre-roll background. No cannabis experience. She was handed the Blackbird and told to figure it out. She hit 160,000 pre-rolls in a single month on one machine. Her team is now tracking every strain in a database, categorizing which ones roll well, which ones need adjustments, and which ones get rerouted entirely based on how they behave at 11 and 12 percent moisture.

Jonathan explains why the Blackbird produces a fundamentally better joint than a cone-based machine and why it comes down to one thing: moisture. Higher moisture flower tastes better, burns cleaner, and preserves the cannabinoids and terpenes that actually make a good joint. Cone machines require operators to dry the material down so far that by the time the product reaches the shelf, the test result it was grown to achieve means very little.

They also get into the pre-roll market itself. Pre-rolls are now the largest category of sales at the mello retail store, ahead of flower. Jonathan explains why he expects pre-rolls to overtake flower in most US markets the same way they already have in Canada. And why the brands that treated pre-rolls as a place to send their leftover material five years ago are now watching the brands that invested in quality automation pull away from them.

Matt talks through the cost per unit math that most operators never discuss publicly, including how dropping from 1.1 grams to 1.04 grams per joint adds up to 6 percent more pre-rolls from the same material, and why every razor blade swap, every torn end, and every bad roll is money leaving the business.

And they close on what is coming next from RollPros, including a banding mechanism for the Blackbird that adds a cigar-style wrap to every joint, hash hole capability on the XXL running at 200 units per hour, and why the cigar manufacturing industry refused to work with them because they are cannabis.

Direct, specific, and the most technically detailed episode of The Blunt Boardroom yet.

Topics covered: RollPros Blackbird 2, pre-roll automation, whole flower pre-roll production, moisture science in cannabis processing, RollPros certification program, cost per unit optimization, pre-roll market growth, hash holes at scale, Blackbird vs. cone machine comparison, cannabis equipment customer service, pre-roll pack formats, mello farm operations.

ABOUT THE GUESTS

Jonathan McFarlane is the Chief Marketing Officer of RollPros, the manufacturer of the Blackbird pre-roll machine. He has been with RollPros for four years and previously served as head of marketing at Mobius Trimmer and spent four years at a cannabis-focused marketing agency in Denver. He started his career in documentary film and content production for professional athletes before entering the cannabis industry in 2016.

Maddie Bailey is the post-production supervisor at mello Cannabis and leads all pre-roll operations at mello farms. She came to mello from a mechanical background in the automotive industry and was tasked with learning and scaling the RollPros Blackbird from day one. She has since built the production system that consistently produces some of the top-awarded pre-rolls in Massachusetts.

ABOUT THE HOST

Matt Richman is the CEO & CFO of mello Cannabis, an award-winning vertically integrated cannabis company based in Haverhill, Massachusetts. A former Deloitte auditor, he entered the cannabis industry in 2017 after two decades in corporate finance, public and private company CFO and COO roles, and M&A advisory.

He is both the CEO & CFO, and the difference comes through in every conversation.

Connect with Matt:
linkedin.com/in/matthew-richman-508aa413
mellocannabis.com

New episodes of The Blunt Boardroom drop twice a month.

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