Automate Pre-Roll Production Without Sacrificing Quality
The Knockbox system solves the core challenge of scaling pre-roll operations: maintaining pack consistency while increasing throughput. Manual filling introduces variance in density, weight, and burn quality—issues that compound when producing hundreds or thousands of units daily.
Precision-Engineered Vibration Technology
Knockbox machines use calibrated vibration frequency to settle ground flower evenly across all cones simultaneously. This eliminates air pockets, prevents canoeing, and ensures every pre-roll delivers the same draw resistance and burn profile your customers expect.
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Dual Density Modes: The
integrated controller lets you toggle between light and tight packs. Soft packs suit flavorful, slow-burning joints, while tight packs maximize product per cone for high-potency offerings.
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Modular Filling Kits: Swap between the
Standard Kit (109mm king size),
Slender Kit (84mm 1 1/4 size), or
Fatboy Kit (120mm large format) in seconds. One machine handles your entire product line.
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Waste Reduction Design: The
spill tray captures overflow material, which you can recycle into the next batch. Combined with the
unload station, you recover 95%+ of loaded material.
Choosing the Right Pre-Roll Workflow
Knockbox machines excel in mid-to-high volume environments where consistency matters more than speed alone. Here's how to integrate them into your operation based on current output and growth plans.
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Home Growers & Micro Producers (100-500 cones/day): The
Knockbox 100 paired with a
Futurola Mini Shredder handles personal stash creation or craft batches for local markets. Fill 100 cones in 2 minutes, then twist and pack.
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Licensed Dispensaries & Co-Ops (500-2,000 cones/day): Stack two Knockbox 100 units side-by-side and feed them from a
Futurola Original Shredder. This two-station setup produces 1,200 pre-rolls per hour with a single operator managing both machines.
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Essential Consumables: Stock
Futurola King Size Cones (6,000-pack bulk cases) and pair with the
Dutch Crown Device to automate the cone-closing step. This attachment folds cone tips perfectly, preventing spillage during transport.
Maximizing ROI with Knockbox Automation
Pre-roll automation pays for itself through labor savings and product consistency. Calculate your break-even point using these real-world benchmarks.
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Labor Cost Savings: Manual cone filling averages 40-60 cones per hour per person. At $18/hour labor cost, you spend $0.30-$0.45 per pre-roll in wages alone. Knockbox operators produce 600+ cones per hour, reducing per-unit labor cost to under $0.03.
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Reduced Material Waste: Hand-stuffing spills 5-10% of ground flower onto tables and floors. Knockbox's enclosed filling chamber and
mix tray system recover spillage, cutting material loss to under 2%.
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Consistent QA Pass Rates: Machine-filled cones exhibit ±0.05g variance across batches versus ±0.15g for hand-filled. This consistency improves QA efficiency and reduces rejected inventory. Want to learn more about optimizing your entire post-harvest workflow? Read our guide on
proper curing techniques to ensure your pre-roll flower delivers peak flavor and potency.
Frequently Asked Questions
How many cones can a Knockbox fill per hour?
The Knockbox 100 fills 100 cones every 2 minutes, translating to approximately 3,000 cones per hour under continuous operation. Real-world production typically ranges from 600-1,200 cones per hour per operator when factoring in loading, unloading, and quality checks. Multiple machines can run simultaneously to scale throughput.
What cone sizes work with Knockbox machines?
Knockbox systems accommodate multiple cone sizes through interchangeable filling kits. The Standard Kit handles 109mm king size cones, the Slender Kit fits 84mm (1 1/4 size), and the Fatboy Kit supports 120mm large-format cones. Futurola pre-rolled cones are engineered specifically for Knockbox compatibility, but most quality cones with consistent dimensions will work.
Do I need a grinder before using the Knockbox?
Yes. Knockbox machines require consistently ground flower for optimal filling. Futurola offers shredders specifically designed for pre-roll workflows, including the Mini, Original, and Mega models that process 0.7-5 lbs in 7 seconds. Proper grind consistency eliminates clumping and ensures even distribution across all cones during vibration filling.
Can I adjust the density of filled cones?
The Knockbox controller includes high and low density modes. Low density creates looser packs for slow, flavorful burns preferred by connoisseurs. High density packs more material per cone for potent offerings or when maximizing product weight per unit. You can switch modes between batches to accommodate different product lines.
What replacement parts should I keep in stock?
Essential spare parts include the cone loader (which experiences wear from repeated cone placement), the mix tray (which contacts flower directly), and a backup power adapter. The controller and unload station are durable components that rarely need replacement. Trimleaf stocks all official Futurola Knockbox parts with fast shipping to minimize downtime.
How does Knockbox compare to manual cone filling?
Manual filling produces 40-60 cones per hour with high labor costs and inconsistent pack density. Knockbox automation delivers 600+ cones per hour with uniform weight and burn characteristics. The vibration-based filling method eliminates hand fatigue while reducing material waste from spillage. Most operations recoup the machine cost within 2-4 months through labor savings alone.
Can Knockbox machines handle sticky or moist flower?
Knockbox performs best with properly cured flower at 58-62% relative humidity. Overly moist material clumps during vibration and fills unevenly. Excessively dry flower creates dust and powder that leaks from cone tips. Proper curing and storage in humidity-controlled environments ensures optimal Knockbox performance and superior pre-roll quality.
Is the Knockbox 100 suitable for small-scale operations?
The Knockbox 100 serves both craft producers and commercial operations effectively. Home growers and micro-cultivators benefit from consistent quality and time savings even when producing 100-300 cones per week. The modular filling kit system means you can start with one cone size and expand your product line as demand grows without buying additional base units.
