Case Study: How Mariani Packing Company Increased Efficiency with Reusable Ag Bins

Mariani Packing Company, founded in 1906 by Paul Mariani, began with a dream to build a business in California. After emigrating from the Island of Vis in Croatia, Paul planted fruit trees in the fertile lands of Santa Clara Valley. As the business expanded, Mariani partnered with other growers to offer a wider variety of fruits. In the 1940s, Paul Jr. revolutionized the industry by introducing the first ready-to-eat, moist dried fruit packaged in retail-ready bags.

Today, Mariani is the world’s largest independently owned producer of dried fruit, with operations in California and Wisconsin, producing over 150 million pounds of product annually. Under the leadership of CEO Mark Mariani, who has been at the helm for over forty years, and President George Sousa Jr., the company remains committed to quality, innovation, and sustainability.

The Challenge: Outdated Bins Slowing Production and Increasing Contamination Risks

Mariani handles an average of 900,000 pounds of fruit daily across its high-volume processing facilities. The fruit undergoes meticulous inspection, washing, drying, and grading with state-of-the-art equipment before being stored in bulk containers.

Previously, Mariani used wood bins during processing, which presented several challenges:

• Food Safety Risks: Wood splinters and contaminants were difficult to detect, especially with dark dried fruits like prunes, raisins, and cherries.
• Inefficient Cleaning: The porous nature of wood bins made cleaning difficult, increasing the risk of cross-contamination.
• Limited Storage Capacity: Wood bins could only be stacked four high, limiting warehouse space.
• Handling & Safety Issues: Heavier and less stable than plastic alternatives, wood bins increased the risk of forklift accidents and falling containers.

To address these challenges, Mariani began converting to ProBin 24-S containers to improve quality control, storage efficiency, and overall processing operations.

The Solution: Integrating ProBin 24-S Reusable Bulk Containers

Mariani transitioned to ProBin 24-S, an FDA-approved, injection-molded plastic bulk container designed for food processing and agriculture storage solutions. Unlike wood bins, ProBins offer a smooth, nonporous surface, which is easier to sanitize and eliminates contamination risks from splinters or hidden debris. Studies show that reusable bulk containers are ideal for farms, orchards, and food processing companies seeking sustainable packaging solutions that meet the high standards of the food industry.

Why Reusable Agriculture Bins?

• Improved Food Safety & Quality Control: The light-colored plastic allows Mariani’s laser sorters to detect foreign materials more easily, ensuring only the highest-quality fruit moves through production. Additionally, reusable harvest bins enable direct storage and mixing of dried fruit, reducing the need for extra handling and minimizing contamination risks.

• Higher Efficiency in Cleaning & Handling: Cleaning speed is critical when processing nearly a million pounds of fruit per day. With reusable bins, Mariani can now wash 480 containers in a single 8-hour shift, significantly improving workflow compared to the labor-intensive process required for wood bins.

• Increased Storage & Space Optimization: One of the biggest advantages of switching to ProBin containers was the ability to stack them higher and more securely than before. Mariani now stacks eight ProBin containers per column, compared to only four wood bins, effectively doubling their storage capacity.

• Enhanced Worker Safety & Operational Efficiency: ProBins are lighter than wood containers, making them easier to maneuver. The interlocking foot design and reinforced columns create more stable stacks, reducing the risk of forklift accidents and falling containers.

The Results: Increased Efficiency, Lower Costs, and Improved Product Protection

Since replacing wood bins with ProBin reusable agriculture bins, Mariani Packing Company has achieved:

• Higher Processing Efficiency: Containers move smoothly through automated sorting, handling, and cleaning systems, reducing downtime.

• Stronger Food Safety Compliance: The smooth, nonporous material prevents contamination, and the MacroLid provides added protection.

• Increased Storage & Space Utilization: Doubling stack heights maximizes warehouse efficiency.

• Reduced Costs & Material Waste: Long-lasting ProBins eliminate frequent replacements and waste associated with wood bins.

The Takeaway: Smarter Packaging for Food Processors

For food processing companies handling high volumes of perishable goods, switching to reusable agriculture bins offers significant advantages in efficiency, food safety, and cost savings. The ability to store, mix, and transport products safely while optimizing warehouse space has made a measurable impact on Mariani’s operations.

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Frequently Asked Questions (FAQs)

What are ProBin 24-S solid-wall, reusable bulk containers?
ProBin 24-S containers are FDA-approved, injection-molded plastic bins designed specifically for food processing. They offer a nonporous, easy-to-clean surface that reduces contamination risks and enhances food safety.

How do ProBin bins improve warehouse efficiency?
ProBin containers can be stacked higher and more securely than wood bins, increasing storage capacity and maximizing warehouse space. Their lightweight design also makes them easier to handle, improving operational efficiency.

Why switch to reusable agriculture bins for food processing?
Reusable agriculture bins, such as ProBin containers, provide enhanced food safety, better storage capacity, and improved cleaning efficiency. They also reduce costs and material waste, making them a sustainable solution for food processors.