A repeatable result in a polystyrene box comes from the warehouse team applying the same sequence on every shipment; putting product in the box and adding coolant is not enough for that.
- Look for breaks or gaps in the body and lid.
- Prepare the product at its target dispatch temperature.
- Place the approved coolant where the specification says.
- Limit product movement without randomly blocking air paths.
- Close the lid promptly and put the label on a visible face.
The step most often skipped is loading warm product and expecting the box to cool it. A passive box does not replace pre-cooling; the starting condition of the product, the box and the coolant, and the loading time, are recorded separately on the dispatch record.
Prepare a reference load for the hardest route: a photo of the layout, the unit count and the closing sequence. A new operator loads from this reference rather than from a verbal description.
