Sorting Returns
Returns are an inevitable part of modern logistics. But a well-organized return process can make the difference between a cost burden and a competitive advantage. This page helps you understand what return logistics involves, when it becomes a bottleneck, and how to optimize it.
Return logistics
Return logistics is the process of organizing, registering, inspecting, and processing goods that are sent back. These can include e-commerce orders, but also surplus products returned from retail.
In essence, return logistics is very similar to your inbound goods flow — with the key difference that return items must be inspected and then assessed to determine whether they can be resold, returned to stock, or sent to another destination.
Why Efficient Return Logistics Matters
Easy (and often free) returns are a key part of the overall customer experience. To ensure that returns can be processed efficiently and without errors, a solid return logistics setup is essential. It all starts with proper packaging and a correct return barcode — two basic ingredients that enable the automatic sorting of returned items.
On average, 60% of online purchases are returned. The cost of handling returns is 400% to 500% higher than the cost of shipping an order. All the more reason to streamline the return process and reduce costs wherever possible.
Common Reasons for Returns
Customers often return items for the following reasons:
- It doesn’t fit (wrong size)
- The product is different than expected
- The item is damaged
- The product doesn’t function properly
- The wrong product was received
- Multiple items were ordered for comparison
- Returning is a customer's right
*) Source: Thuiswinkel.org
Integrate Return Logistics into Your Existing Logistics Flows
Efficient return handling using your automated sorting system
Returned goods can be processed as inbound flows on an automated sorting machine. Both outbound orders and inbound returns can be handled on the same sorter. Returned items are automatically sorted into predefined categories:
- Stock replenishment
- Resale (via cross-docking)
- Inspection (VAS location)
- Repair
- Disposal
- Smart software integration is key
A seamless connection between your WMS, return portal, and labeling system is essential. It enables:
- Fast processing of returns
- Accurate refunds
- Real-time inventory updates
- VAS and cross-docking for direct reintegration
Returns can be routed via a Value Added Services (VAS) location or cross-docked directly into new orders or back into stock. Our consultants frequently encounter similar cases in practice, and their experience—combined with our sorting solutions—can help you reduce costs and optimize your return logistics.
Is automated return management right for your organization?
In essence, any company using an automated sorter for order fulfillment is also suited for automated return handling. For the sorter, returns are simply inbound goods. However, your return logistics must be well-organized. Proper packaging and accurate (return) barcodes or QR codes are crucial. When these elements are in place, returns can be automatically sorted according to preset criteria.
When is return automation worth considering?
Return automation is interesting when:
- You need to process at least 3,500 returns per hour
- Fast administrative handling is important
- Minimal manual labor is preferred
- You want to maintain real-time inventory accuracy
- You aim to minimize error margins
Return automation is not suitable when:
- Products need to be individually inspected
- The volume of returns is low
- Returns are sent directly to resellers without inspection
Role of DistriSort
DistriSort is here to advise and support you.
We work with both large and small clients, and we see real-world examples across the Netherlands and abroad. Our goal is to help you identify opportunities for cost savings and process improvements. We’re honest and sometimes critical, but always focused on one clear objective: improving your logistics flows, including return logistics.
What we offer:
- Seamless software integration
We provide software that integrates smoothly with your existing WMS, regardless of the supplier. - ROI Scan
Based on your order data, DistriSort performs a reliable ROI scan. This gives a clear estimate of the payback period (typically 1–3 years) for investing in an automated sorting solution. - Computer Simulation
Compare different systems and applications through simulation. We can model your inbound, outbound, and return flows using various products and sorting solutions. - Real-Life Demo
Sort your products live in our Innovation Center. We offer the opportunity to test your items on different sorting machines, so you can experience the process firsthand. If you're unable to visit, we’ll create a video demonstration for you. - Tailor-Made Solutions
As a system integrator, we can install a fully customized sorting solution tailored to your specific needs.
Sectors and Use Cases
DistriSort’s strength and expertise lie primarily in high-throughput single-item sorting — the sorting of individual items. For return logistics, these are the most relevant sectors:
- E-commerce: Fast reintegration of sellable items into inventory
- Apparel & Fashion: High return rates, often involving small items
- Cosmetics: Sealed packages can be returned to stock or routed via cross-docking
- Media / Books: Standardized formats, easy to stack and handle
- Post & Parcel: Highly varied in shape and weight
- 3PL (Third-Party Logistics): Multi-client return flows are managed through a single system
- Pharma: High volumes of small, lightweight packages
FAQ Returns
Specific questions or can't find your query? Contact us!
Yes! If the product fits on a sorting machine (in terms of size and weight), the return process can be automated.
No. DistriSort’s sorting solutions can handle all logistics flows automatically — inbound, outbound, and returns — using the same system.
The system sorts items based on predefined criteria, such as:
- Cross-docking (immediate resale)
- Return to stock
- Refurbishment & Value Added Services (VAS)
- Resale to liquidators
- Donation
- Disposal
Virtually all types.
From standard consumer (e-commerce) returns to product recalls or store inventory returns (e.g. leftover stock after a sales period).
