Did you check the return value when unpacking? Error messages are not indicated in the standard output stream, so the array will be empty if something fails.
<?php
$result = array();
exec("unzip archiv.zip", $result, $returnval);
print_r($result);
print_r($returnval);
?>
Does unpacking work as expected? It may require overwriting, etc., if the files already exist and stop the workflow. This result will not be recorded as a result.
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