Pre-Rolled Cones: Engineering Supply Chain Independence

Project Overview

The Pre-Rolled Cones project represents my strategic transition from relying on third-party suppliers to developing custom-designed, branded cones specifically engineered to work perfectly with the packNpuff loader. These organic hemp cones were created with precisely calculated dimensions to optimize functionality while simplifying customer choice through a streamlined product lineup.

The Problem

As the packNpuff gained market traction, several critical supply chain vulnerabilities emerged:

1. Supply uncertainty: Dependency on a single well-known brand led to frequent stockouts
2. Production bottlenecks: Inability to fulfill packNpuff orders when cone supplies were depleted
3. Lack of control: No influence over quality, dimensions, or materials used in third-party cones
4. Business continuity risk: Supply shortages directly impacted revenue potential
5. Brand inconsistency: Multiple component brands created a fragmented customer experience

These issues became increasingly problematic as sales volume grew, threatening the sustainability of the business model and limiting growth potential.

The Solution

I developed a comprehensive strategy to address these challenges:

1. Custom manufacturing partnership: Established direct relationships with overseas manufacturers
2. Technical standardization: Engineered consistent aspect ratios across different cone sizes
3. Material specification: Standardized on organic hemp paper for sustainability and quality
4. Product simplification: Offered only two sizes (renamed "standard" and "large" for clarity)
5. Ethical manufacturing verification: Personal factory visit to confirm labor practices
6. Perfect compatibility: Custom dimensions designed specifically for packNpuff v2

This approach resulted in cones with precise specifications that perfectly complement the packNpuff loader while establishing complete control over a critical supply chain component.

Technical Implementation

Engineering Challenge

The most significant technical challenge involved standardizing the aspect ratio between different cone sizes. Traditionally, standard (1¼) and large size cones have different proportions, which would require separate internal dimensions within the packNpuff.

I solved this by redesigning the standard size cone to match the aspect ratio of large size cones:

• Standardized geometry: Both sizes now share the same proportional relationship between top diameter, bottom diameter, and height
• Dimensional precision: Standard cones maintained at 84mm height versus 109mm for large cones
• Universal compatibility: packNpuff v2 designed around a single aspect ratio that works with both proprietary and major third-party cones

Manufacturing Partnership

After extensive research and multiple supplier iterations, I established a relationship with a leading Indonesian manufacturer who:

• Offers organic hemp paper options
• Maintains consistent quality control standards
• Provides custom design capabilities
• Operates with ethical labor practices

A personal visit to their Bali facility in 2023 confirmed they maintain excellent working conditions and prioritize female employment, making them one of the island's largest private employers.

Challenges and Solutions

Supplier Identification

Challenge: Finding a direct manufacturer willing to produce custom dimensions in sustainable materials proved extremely difficult, with many intermediaries obscuring direct factory access.

Solution: Persistent research eventually led to a manufacturer who not only met all requirements but proved to be one of the industry's major suppliers, including to the original brand I had relied upon.

Packaging Logistics

Challenge: Initially, I ordered bulk unpackaged cones and worked with an ethical repackaging service in the US that employed marginalized workers, creating significant logistical complexity.

Solution: While this arrangement supported an important social mission, it proved unsustainable from a business perspective. Future orders will include manufacturer packaging to improve scalability.

Customer Acceptance

Challenge: Some customers expressed loyalty to established cone brands despite functional equivalence.

Solution: Emphasized the perfect compatibility with packNpuff and consistent availability as key selling points, while maintaining functional compatibility with third-party cones for customer flexibility.

Outcomes and Impact

The transition to custom pre-rolled cones has delivered significant business benefits:

• Supply chain control: Eliminated stockouts and production delays
• Brand consistency: Complete product ecosystem under one brand
• Product messaging: Ability to market "perfectly designed" compatibility
• Business sustainability: Addition of a consumable product line with repeat purchase potential
• Simplified customer experience: Reduced decision paralysis through limited, clear options
• Ethical sourcing: Confidence in manufacturing conditions after personal verification

Future Development

The roadmap for pre-rolled cones includes:

1. Streamlined packaging: Transitioning packaging to the manufacturing source
2. Inventory optimization: Improving forecasting to maintain ideal stock levels
3. Potential new materials: Exploring additional sustainable paper options
4. Maintaining size simplicity: Continuing to focus on just two sizes with clear naming conventions

Technologies Used

• Materials: Organic hemp paper
• Design: Custom aspect ratio calculations for dimensional consistency
• Manufacturing: Direct partnership with international production facility
• Supply Chain: Strategic transition from dependency to ownership

This project demonstrates how vertical integration through custom component design can address critical business vulnerabilities while simultaneously improving product functionality and customer experience.