Common Issues with Infused Pre-Roll Machines and How to Fix Them
Infused pre-roll machines are essential for large-scale cannabis production, allowing brands to create consistent, potent, and professional-looking products.
However, even the best machines can face common operational issues, leading to downtime, uneven dosing, or product rejection.
This article breaks down the most frequent issues, why they occur, and how you can fix them, ensuring your infused pre-roll production stays efficient and high quality.
1- Inconsistent Infusion Dosage
In infused pre-rolls, precision is everything. If the machine doesn't inject the correct amount of concentrate (e.g., hash oil or distillate), you risk creating pre-rolls that are too weak, or worse, too strong. This not only affects product quality and brand trust but also poses serious legal and compliance risks, especially in regulated markets.
Common Causes
Clogged nozzles due to residue buildup from sticky concentrates
Viscosity issues where the concentrate is too thick or too thin for accurate dosing
Improper calibration of the infusion pump
Solutions
Clean infusion nozzles daily and perform deep cleans weekly
Use concentrated heaters to maintain optimal fluidity
Recalibrate machines for each new batch or concentrate type
2- Machine Jamming During Operation
Jamming is one of the most frustrating problems in infused pre-roll production. It brings everything to a stop, wasting time, material, and money. It can happen during cone loading, filling, or twisting. If not fixed quickly, jams can damage the machine or create misaligned pre-rolls.
Common Causes
The cannabis material is too sticky or wet
Grind size is too fine or inconsistent
Overfilling the machine with too much flower or concentrate
Solutions
Keep cannabis at 10–12% moisture to avoid clumps
Use a consistent, medium grind ideal for pre-rolls
Stick to machine load limits and avoid overpacking
3- Uneven Packing in Pre-Rolls
A pre-roll that burns unevenly or collapses mid-smoke is usually the result of uneven packing. This leads to customer dissatisfaction and product returns. Uneven density can also make the cone twist improperly or cause it to bend during infusion.
Common Causes
Inconsistent cannabis density or particle size
Incorrect vibration or tamping settings on the machine
Manual interference from untrained operators
Solutions
Standardize your flower moisture and grind before use
Adjust vibration settings based on material type
Train operators to monitor fill levels and stop for adjustments
4- Clogging in Infusion Lines
Infused pre-roll machines use narrow lines or nozzles to inject concentrates. When not maintained correctly, clogging occurs, leading to inaccurate dosing, pressure issues, and downtime. Over time, this can damage the machine or ruin batches.
Common Causes
Sticky residue buildup from THC oils or waxes
Infrequent cleaning of internal lines
Using thick or incompatible concentrates
Solutions
Clean infusion lines after every production shift
Use filtered, winterized concentrates with smooth flow
Keep concentrating on warming to maintain ideal viscosity
5- Software or Sensor Errors
Modern infused pre-roll machines rely on automation and sensor technology to ensure precision. If the software malfunctions or a sensor fails, it can cause wrong fills, missed cones, and full system shutdowns. This is one of the more technical problems that requires attention.
Common Causes
Outdated machine software
Misaligned or dirty sensors
Electromagnetic interference from other equipment
Solutions
Keep your software updated with the latest firmware
Inspect and clean sensors regularly
Use shielded cables and proper grounding to reduce interference
6- Poor Maintenance and Overuse
Like any mechanical system, infused pre-roll machines require routine maintenance. If neglected, components wear out faster, parts become misaligned, and you end up with more frequent breakdowns. Overuse without cooldown periods can also burn out key components.
Common Causes
No regular cleaning or part replacement schedule
Running machines continuously without rest
Ignoring warning signals or minor malfunctions
Solutions
Follow a weekly and monthly maintenance checklist
Allow cool-down periods after long production runs
Train staff to identify and report early warning signs
7- Cone Misalignment and Twisting Failures
If the cones are not properly aligned or twisted, they may burn improperly, leak concentrate, or be rejected during quality control. Misalignment during filling or twisting can damage the cone structure or cause a crooked or open-ended pre-roll.
Common Causes
Incorrect loading of empty cones into the machine
Worn-out mechanical parts that affect alignment
Calibration errors in the twisting mechanism
Solutions
Train staff to load cones carefully and evenly
Replace worn-out cone holders or motor arms
Calibrate twist settings for each cone type (e.g., King Size vs. Slim)
8- Incorrect Temperature Control for Infusions
Temperature plays a crucial role when infusing pre-rolls with cannabis concentrates like distillates, waxes, or live resin. If the machine fails to maintain the correct temperature, the concentrate may not flow properly or may degrade, leading to product inconsistency and wasted material.
Common Causes
Malfunctioning or uncalibrated heaters
Poor insulation in concentrated containers
Using concentrates not formulated for machine compatibility
Solutions
Use machines with built-in temperature regulators like the Jiko Infused Pre-Roll Machine
Monitor temperature with infrared or digital thermometers
Work with concentrate suppliers to ensure product consistency under heat
9- Compatibility Issues with Different Cone Sizes or Types
Not all infused pre-roll machines support every cone type. Some machines are optimized for specific sizes (e.g., 0.5g, 1g) or shapes (like slim or king size). Using incompatible cones can cause misfeeds, poor filling, or improper sealing.
Common Causes
Cone type not listed in the machine’s specifications
No adjustments mwere ade when switching cone sizes
Inaccurate cone placement by operators
Solutions
Check the manufacturer's cone compatibility list before purchase
Use adjustable cone trays or adapters if available
Train operators on size-specific settings and loading techniques
10- Undertrained or Unskilled Machine Operators
Even the best machinery can’t fix human error. When machine operators lack proper training or don’t understand the machine’s functions, errors multiply, leading to clogs, product loss, downtime, and machine damage.
Common Causes
No standardized training process
High employee turnover without retraining
Not documenting past issues or fixes
Solutions
Develop a consistent training program with SOPs (standard operating procedures)
Schedule monthly refresher sessions for staff
Keep a log of machine issues and solutions to learn from patterns
Frequently Asked Questions
How often should I clean an infused pre-roll machine?
Daily cleaning is recommended, with deep cleaning done weekly. This helps avoid clogs, residue buildup, and performance drops.
Why are my infused pre-rolls unevenly burning?
This is often due to inconsistent packing or moisture content. Ensure even grind size and proper tamping settings.
Can I use any concentrate in my infusion machine?
No. Use only concentrates that are compatible with your machine’s viscosity and temperature handling capabilities.
What’s the best way to avoid cone misalignment?
Regularly inspect cone holders, calibrate settings, and ensure cones are loaded evenly with no overlap.
Smooth Production Starts with Prevention
Avoiding problems with infused pre-roll machines isn’t just about fixing things when they break, it’s about preventing the issues before they happen. From consistent maintenance to staff training and proper material prep, small steps make a big difference. Taking the time to understand each part of the process helps ensure your product remains top-tier, every single time.
Ready to Fix Your Pre-Roll Problems for Good? If you're tired of dealing with these common infused pre-roll machine issues and want to optimize your production line, you're not alone. Get expert help and cutting-edge solutions today.
Contact Sorting Robotics Now and take your cannabis pre-roll operation to the next level!
