What if I told you there was a huge opportunity in the pre-roll category, a mostly untapped segment with a built-in customer base and an instantly recognizable product that drives millions of dollars in sales?

For years, the pre-roll category has been one of the fastest-growing segments in legal cannabis, totaling nearly $3.6 billion in sales in 2025 in the markets tracked by cannabis analytics firm Headset.  Consumers love the convenience, portability, and accessibility of pre-rolls, and retailers appreciate their consistent sell-through as low-cost, high-margin add-ons at checkout.

But within that booming category, one product type stands out as an underdeveloped opportunity: the blunt.

Blunts: A Classic Format with Modern Market Potential

Despite the innovations in vapes, edibles and other product forms since the early days of the industry, traditional smoking remains king. In fact, New Frontier Data found that about 60% of cannabis consumers still list the classic joint as their primary consumption method. 

But if you look a little deeper into the data, it reveals that the third most popular consumption method is the blunt, with 33% of respondents listing it as a go-to.

However, when we look at the actual sales data, blunts barely register. According to Headset, pre-rolled blunts currently make up less than 1% of total pre-roll sales. Of the $3.6 billion generated by pre-rolls in 2025, the “Cannagar/Blunt” segment accounted for roughly $16.3 million in sales.

However, because of how Headset parses the data, all infused blunts fall into the “connoisseur/infused” segment, not the blunt segment, skewing the final numbers.

When we look specifically at the products containing the word “blunt,” we get a clearer picture. Collectively, those “blunt” products sold 8.5 million units and generated more than $148 million in revenue nationwide.

That demonstrates a demand for the product. And for pre-roll producers and processors, that’s the definition of a growth opportunity. 

The Evolution of the Modern Pre-Rolled Blunt 

Traditionally, a blunt is a cannabis cigar; flower rolled in a tobacco leaf wrap instead of paper. The thicker wrap produces a slower burn, richer flavor, and a distinctive mouthfeel that many smokers prefer. The name itself comes from the “blunt” style of machine-rolled cigars, such as Phillies Blunts, which became synonymous with cannabis culture in the 1980s and ‘90s, thanks in large part to hip-hop’s East Coast icons.

But as part of their regulations, each modern cannabis market prohibits combining tobacco and cannabis products, which led to the development of nicotine-free blunt wraps designed to deliver the same slow burn and satisfying texture, but without the tobacco.

Today, most modern blunts are wrapped in hemp wraps, though tea leaf and botanical alternatives such as goji berry or palm leaf are also popular.  Modern, pre-rolled blunts also tend to include filter tips, whether standard pre-rolled joint like paper filters, spiral filters or even premium options like wood, glass and ceramic options, to cool the smoke and elevate the experience.

Pre-roll blunts can also be found in both tube and pre-rolled cone forms, with the latter being introduced to the market by Custom Cones USA, and are usually found in the 1-gram to 2-gram range, as blunt smokers tend to want longer smoking experiences.  

What Options Exist for Producers?

Brands looking to enter the blunt space have more options than ever. The first choice is shape – cone or tube – since that determines the filter style, filling process and production equipment.

Cone-style blunts, first introduced to the market by Custom Cones USA, are the easiest entry point for companies already producing joints. They’re compatible with standard cone-filling machines and use familiar “W-style” paper filters.

Tube-style blunts can open up a world of premium customization. They typically use larger filter tips (spiral paper, wood, glass, or ceramic) and can accommodate larger weights, making them ideal for high-end SKUs. However, a tube-filling conversion kit may be needed to adapt existing production lines, however.

After you’ve chosen a shape, the next question is what kind of wrap to use:

• Hemp wraps: The industry standard for a reason; natural, slow-burning, and tobacco-free.
• Hybrid hemp wraps: A Custom Cones USA innovation that retains the rich hemp flavor while resisting moisture and cracking. 
• Tea leaf wraps: Offer subtle cocoa and vanilla notes for a smoother, lighter smoke.
• Botanical wraps: Specialty options like goji berry add flavor and vibrant visual appeal.

Each wrap type can be paired with custom filter tips and cigar-style bands to reinforce brand identity on the shelf. 

Why The Pre-Rolled Blunt Category Matters

When you combine consumer preference (33% blunt users) with sales data ($148+ million and growing), the takeaway is clear: the blunt market may be underdeveloped, but it’s not underloved.

For producers, that means a Blue Ocean opportunity, a chance to claim early leadership in a space that’s ripe for innovation. With the right materials and machinery, transitioning from pre-rolls to blunts is straightforward, scalable and potentially brand-defining.

Whether you’re adding a new SKUs to your pre-roll line or launching a dedicated blunt brand, now is the time to invest and make a mark in this emerging segment.