Make Returns Less Painful and More Profitable

July 23, 2025

Returns can cost retailers millions in lost revenue and labor.

MHS Lift helps businesses design automated returns zones with barcode scanning, vision sorters and triage workflows – reducing processing time and reclaiming resale value.

Why are returns so costly for warehouses?

Returns don’t just hurt revenue – they clog up workflows, take up valuable space and often require manual re-sorting. Every extra touch point adds cost and reduces resale potential.

Common challenges include:

  • Unsorted inbound returns
  • Lack of defined triage zones
  • Labor-intensive inspections
  • Poor data capture and tracking

Fixing these issues is key to making returns faster and more profitable.

What does an optimized returns zone look like?

MHS Lift helps create high-efficiency returns areas designed to reclaim value. Key features include:

  • Barcode tunnels and vision sorters for automated identification
  • Triage zones to categorize items: resale, refurbish, recycle
  • Workflows integrated with your WMS for real-time updates
  • Return shelving configured for quick re-slotting into inventory

The goal is to minimize touches and streamline disposition decisions.

How can automation increase returns profitability?

Automation reduces labor costs and speeds up sorting:

  • Items can be scanned and sorted without human intervention
  • Vision systems detect item condition and route accordingly
  • WMS integration enables real-time inventory reallocation

These changes increase resale rates and shorten restock cycles.

Who benefits most from returns optimization?

We see strong ROI for:

  • E-commerce retailers with high return volumes
  • 3PLs managing returns on behalf of brands
  • Apparel and electronics distributors with variable item conditions
  • Facilities retrofitting for reverse logistics

FAQ

Q: What equipment do you need to automate returns?
A: Vision scanners, barcode tunnels, WMS integration and modular shelving or conveyor systems are common components.

Q: Can MHS Lift retrofit my existing warehouse?
A: Yes. We specialize in retrofit designs that enhance existing layouts with minimal disruption.

Q: How do triage zones work?
A: Items are sorted into categories like resale, refurbish or discard based on rules you define – increasing recovery rates.

Q: Is automation worth the investment for small returns volumes?
A: Even moderate returns volumes can benefit from better workflow design. MHS Lift can help you scope a right-sized solution.

Struggling with returns?
Request a workflow audit from MHS Lift and discover how better design and automation can help you recapture revenue and cut returns labor.