How Pick and Pack Robots Speed Up Cannabis Packaging
The cannabis industry is growing fast, and so is the pressure to keep up with consumer demand while staying compliant and efficient. Traditional packaging methods—manual counting, sorting, labeling, and boxing—are often too slow and error-prone to support high-volume operations. That’s where pick and pack robots come in. These advanced automation systems are transforming cannabis packaging by streamlining repetitive tasks, boosting accuracy, and reducing labor costs. Whether you’re handling flower, pre-rolls, or infused products, integrating robotic pick and pack systems can accelerate throughput and elevate your entire fulfillment process.
The Cannabis Boom and the Packaging Bottleneck
The legal cannabis industry is experiencing record-breaking growth—and it’s not slowing down. According to New Frontier Data (2023):
Legal cannabis sales in the U.S. grew by 29% from 2018 to 2023.
This rate is double the national economic growth rate.
Pre-rolls, vape cartridges, and infused products are leading the charge.
So, what’s the problem?
This growth has outpaced traditional production workflows—especially packaging.
Manual Packaging: A Productivity Roadblock
Most cannabis producers still rely on manual labor to package products like:
Pre-rolls
Vape cartridges
Jars of flower or infused items
But manual processes are:
Slow: On average, a human can package 40–50 units per hour (MJBizDaily, 2021).
Labor-intensive: It takes multiple people to sustain packaging lines.
Error-prone: Inconsistent fills, crooked joints, and sloppy infusion damage quality and brand trust.
A 2021 MJBizDaily survey reported:
62% of cannabis producers cite labor shortages and packaging delays as top operational challenges.
45% say inconsistencies in product quality stem from manual labor.
The Bottleneck is Real and It’s Costly
A delay in pre-roll production can mean missed dispensary deadlines.
A poorly packed vape cart may result in returned products or lost shelf space.
Scaling with humans alone creates a chokehold on growth.
In today’s market, speed and accuracy aren’t optional—they’re the baseline for survival.
Enter Pick and Pack Robots
These intelligent machines are transforming how cannabis is packaged—automating repetitive tasks and freeing human teams for higher-value roles. Think:
Robotic arms that pick pre-rolls off a conveyor.
AI vision systems that guide grippers to pack jars into shippers.
Precision systems that never tire, misplace, or fumble.
We’ll break down how these robots work—and how companies like Sorting Robotics are setting the gold standard for packaging automation in cannabis.
What Are Pick and Pack Robots?
Pick and pack robots are automated systems designed to handle and package finished products at the final stage of production. They don't just move products—they do it with speed, consistency, and intelligence.
Core Functions
These systems are built to:
Pick: Grab finished items like pre-rolls, vape carts, or jars.
Orient: Adjust the item’s position as needed using vision systems.
Pack: Place the item accurately into a container—whether it's a shipping tray, display box, or pre-roll tube.
Key Components
Pick and pack robots typically include:
Robotic Arms: Provide fast and precise motion.
Grippers: Mechanical or suction-based tools to handle delicate items.
Vision Systems: Cameras and sensors to identify item placement and orientation.
Control Software: AI-powered logic to optimize tasks and adjust in real time.
How It Applies to Cannabis
In the cannabis industry, packaging involves:
Handling fragile or sticky materials (like infused pre-rolls or oil-filled vape carts).
Maintaining product integrity (no crushed cones or leaking carts).
Meeting regulatory compliance (accurate labeling, no cross-contamination).
Pick and pack robots solve these with:
High-speed automation
Repeatable precision
Consistent quality control
How Pick and Pack Robots Speed Up Cannabis Packaging
Speed and consistency are the lifeblood of modern cannabis production. Pick and pack robots offer both along with measurable gains in output, labor efficiency, and product quality.
Let’s break down four core advantages:
1. Blazing Throughput
Pick and pack robots radically boost production speed, outperforming manual labor by orders of magnitude.
Manual Labor:
Average human worker: 40–50 units/hour (MJBizDaily, 2021)
5-person team: ~2,000–2,500 units/day
With Robotics:
Omni: Fills 100 vape cartridges in 75 seconds
→ That’s 4,800 units/hour with one operatorStardust: Packs pre-rolls in minutes, not hours
→ Shipper loads that once took a full team now need one or two operators
Other competitors like High Tek USA advertise:
10 pouches per minute (600/hour)
Labor reduced from five to two packers
Output tripled to 6,000 units/day
But Sorting Robotics goes further—focusing not just on throughput, but targeted performance in cannabis-specific formats like:
Fragile pre-rolls
Sticky infused joints
Delicate vape carts
These aren’t bulk gummies or edibles—they demand precision.
2. Precision That Scales Quality
In cannabis, packaging isn't just about speed—it’s about consistency and brand reliability.
Problems with Manual Packaging:
Misaligned joints
Inconsistent concentrate levels
Off-weight vape carts
Irregular dusting or presentation
A 2021 MJBizDaily report found:
45% of cannabis firms cited quality inconsistencies due to human error
Robotic Precision:
Jiko: Adjusts temperature and pressure for perfect concentrate infusion
Omni: Fills every cart to exact specs—no underfills or overflows
Stardust: Uses vision-guided dusting for even coverage, then places each pre-roll with care
Unlike systems that just "catch mistakes" (e.g., High Tek’s checkweigher), Sorting Robotics builds quality in from the start.
No waste. No errors. No complaints.
3. Labor Savings Without Layoffs
Automation isn’t about replacing people it’s about elevating them.
The Cannabis Labor Reality:
High turnover: 20% annually in cannabis packaging roles
Repetitive work causes fatigue and errors
Most producers struggle to find skilled packaging labor
Robotics Change the Game:
Omni reduces vape-filling crews from 3–4 people to just one
Stardust cuts pre-roll packers in half
Sorting Robotics clients redirect labor to:
Quality control
Customer service
Sales and distribution
Packaging World (2024) notes that High Tek’s bagger reduced teams from five to two, tripling daily output.
And according to MJBizDaily:
59% of cannabis firms say automation lets them reassign staff to more valuable roles
Our mission isn’t to eliminate jobs—it’s to free teams from the grind and let them focus on growth.
4. Adaptability for a Dynamic Market
Cannabis isn’t a static industry. Trends shift fast—from donut joints and rosin-infused pre-rolls to microdosed vapes and new jar sizes.
The Problem:
Manual packaging lines are rigid
Reprogramming traditional robots takes days
New product formats often mean new equipment
Our Advantage:
Jiko+ can shift from sauce to rosin infusion with a few taps
Omni adjusts fill volume for any cart size via touchscreen
Stardust’s AI learns and adapts packing patterns on the fly
Even competitors like Canapa offer modular setups, but they lack cannabis-specific engineering.
At Sorting Robotics, every robot is built for this market from software to suction cup.
The Broader Industry Shift
Cannabis isn’t the only sector embracing automation but it’s one of the fastest growing. As demand for packaged products skyrockets, producers across industries are turning to robotics to unlock speed, scale, and reliability. Cannabis is simply following a proven blueprint—just with more complexity.
1. Automation Is the New Standard
Across CPG, pharma, and food packaging, pick and pack robotics are now non-negotiable:
Beverage packaging has seen robotic adoption cut processing time by up to 50% (Packaging World, 2024)
ABB’s GoFa cobots now average 300 picks/hour in industrial settings
73% of cannabis companies plan to increase automation investments by 2025 (MJBizDaily, 2021)
In short: industries that automate stay ahead. The rest fall behind.
2. Why It Matters for Cannabis
The cannabis industry is uniquely suited for pick and pack tech:
Products are fragile (pre-rolls), sticky (concentrates), or inconsistent in shape (jars, tubes)
Packaging rules vary by state, making manual adjustments slow
Demand is product-specific: donut joints, live rosin carts, dusted pre-rolls, etc.
Manual teams can’t keep up with this complexity. Robots, on the other hand, thrive in it.
Automation isn’t just about speed. It’s about handling variability at scale—exactly what cannabis demands.
3. How Sorting Robotics Supports the Shift
We don’t just build tools we help lead the transition with:
Training & on-site onboarding
Modular machines that scale as you grow
24/7 support for high-volume operations
Analytics dashboards to drive smarter production decisions
While other providers focus on conveyor belts and generic arms, we deliver a full cannabis workflow solution, powered by robotics.
4. The ROI Is Clear
Let’s talk about the bottom line. Automation isn’t just a tech flex—it’s a financial lever.
Consider these cost-saving metrics:
Labor reduction: Stardust and Omni cut packaging teams in half
Error reduction: AI removes human inconsistencies
Uptime: Robots operate 24/7 with near-zero downtime
Payback period: Clients like High Tek reported 18-month ROI; Sorting Robotics’ clients often hit ROI in under a year
Automation pays for itself fast.
5. Risk of Staying Manual
Still relying on hand-packed pre-rolls or vape carts?
Here’s what that risks:
Missed dispensary deadlines = lost shelf space
Inconsistent dosing or fill levels = compliance issues
Burned-out staff = high turnover + retraining costs
Scaling struggles = inability to meet demand spikes
The longer you wait, the harder it gets to catch up. The market won’t slow down for anyone.
Frequently Asked Questions
1. How fast can pick and pack robots really work?
Pick and pack robots like Omni can fill 100 vape carts in just 75 seconds, resulting in an output of up to 4,800 per hour. This is a 100x improvement over manual labor.
2. Can these robots handle different product types?
Absolutely. Sorting Robotics machines are designed to handle a variety of cannabis products, including pre-rolls, vape cartridges, and infused jars, with quick reprogramming for new product types.
3. How easy is it to switch from manual packing to automation?
Switching to automation is straightforward with Sorting Robotics. We provide on-site training, plug-and-play systems, and 24/7 support to ensure a smooth transition with minimal downtime.
4. What are the labor savings with automation?
On average, companies that adopt our systems report a 50% reduction in labor costs. For instance, Stardust can reduce a five-person team to two, while tripling output.
5. What happens if a machine malfunctions?
We offer 24/7 technical support, and most issues can be resolved remotely through our diagnostic system. Additionally, our robots are designed with low-maintenance features and are easy to troubleshoot.
6. How do these robots help with product consistency?
Robots like Jiko and Stardust ensure uniform infusion, precise fills, and consistent dusting every time. AI-powered vision systems eliminate human errors, ensuring consistent product quality at scale.
Speed Meets Craft
Sorting Robotics brings speed, precision, and scalability to cannabis packaging. Our tailored solutions help producers meet the growing demands of the market while ensuring high quality. Ready to transform your packaging? Request a demo today and let’s accelerate your operation.
