An empty foam box is light but bulky, so it is the last thing warehouse planning thinks of: it spreads over the floor and ends up under heavy cartons. Direct sun slowly yellows and embrittles the foam surface, so boxes sit in a dry, closed area away from windows and doors, off wet pallets and outer walls.
In the stack, no heavy load goes on top and nobody steps on the boxes to reach the ones behind, because the bottom layer deforms under long pressure. A box that is crushed, soiled or out of shape is taken out of ready stock.
Every box is labelled with SKU, dimensions and receipt date. Look-alike models with different inner volumes then do not get mixed, and first-in first-out rotation stops old boxes ageing at the back of the shelf.
