Returns are a fact of retail

Retailers need to maintain efficient returns systems in their warehouses to retain customers, maximise margins and remain competitive, says Edward Hutchison, UK Managing Director of BITO Storage Systems.

Returning goods has become as an established part of shopping as buying them, since being accelerated during the era of growth in online shopping, where goods are purchased without being tried. The free returns promise carried over to all retail channels, including the high street, and has created a situation in this ultra competitive sector where the unconditional invitation of free return of goods has become enshrined. Returns being limited only to occasions when a retailer failed to match customer expectation has become a distant memory.

This has led to an evolution in shopping habits where consumers, taking free returns for granted, purchase multiple sizes or varieties in the knowledge that they can be returned at no cost. This practice is felt acutely in fashion retail, where shoppers are now accustomed to buying clothing and shoes in a variety of sizes in the knowledge that they will send back any unwanted items.

This can be clearly seen in the returns of online purchases by category in the UK in 2022, as shown by Statista Global Consumer Survey published in May of this year. It asked: ‘Which of these kinds of articles have you sent back after an online order in the past 12 months? Clothing topped the list of items people shop for by far, with almost a third of purchases returned (32%). Shoes come next (15%). All other categories follow some way behind, being evenly distributed between 3% and 8% – though 51% said they didn’t send anything back.

However, there is of course a cost to processing a return and this is leading some retailers to question the economics of free returns and to consider invoking a charge for customers. Such thoughts may not go down well with consumers, some 89% of who identify ease of returns as their top priority when purchasing online, according to data from delivery experience platform Sorted. Research from market researcher Appinio found that 71% of UK consumers would avoid shopping online if they were required to pay to return the items. It will be interesting to see what happens. But irrespective of whether a charge is imposed or not, returns still need to be processed with maximum efficiency.

Indeed, dealing with a return correctly does provide the retailer with an opportunity for positive customer sentiment, potentially increasing customer loyalty and to gain customer advocacy. Having a low-cost, simple yet effective and above all efficient returns processing pathway, will allow returned goods to be placed back on sale as quickly as possible.

The logistics sector has developed solutions to help returned goods to be processed as quickly as possible to gain the maximum value through reintroducing the goods back into stock. For many retailers now, returns are a large and important element of their inventory.

This makes the selection of the appropriate shelving system, container transport, picking methods, as well as the complete internal warehouse processes, a vital factor for an efficient returns system.

BITO provides many products and solutions that contribute to this aim. For example, pallet racking can be configured with a single pallet bay level and shelving above to provide locations for unpalletised ‘returned to stock’ items.

When using BITO’s galvanised shelving for returned items, dividers can be placed on a shelf to help organise stock simply. They can be easily moved to change the size of compartments and can clearly identify new products, for example, at a glance or separate product lines or returns.

To speed the movement of returned goods back to stock, a driverless container transporter, such as the LEO Locative from BITO, makes a smart addition to a warehouses. It helps to reduce travel times for returns as well as other tasks.

Proactive action to reduce returns can be instigated by retailers handling large numbers of items. Deploying order picking systems with minimal error rates will reduce picking errors in e-commerce. This will not only result in higher customer service levels, but will also help to eliminate incorrect orders in fulfilment as a cause of returns.

A sophisticated and highly efficient returns processing system is critical to success in many sectors and can be decisive for a business’ profitability. BITO distribution systems massively optimise order and returns logistics, improving online retailers’ competitiveness. They meet the e-commerce sector’s current demands for flexibility, speed and maximum accuracy. As a result, logistics specialists can optimise goods flow and organise returns logistics so that returned products promptly show back up in the system.

Ferag launches to UK market

Ferag, a global leader in advanced conveying and sortation solutions, has launched its hi-tech, Swiss engineered overhead pouch and sorter systems to the UK market. The technology offers retail, ecommerce, automotive and general merchandise businesses reliable, high-performance conveying and sortation at speeds of up to 12,000 units per hour.

Based in Zurich, Ferag has its origins in the international print industry, where ultra-reliable, high-speed conveying technology is essential to the time-critical production of newspapers with daily print runs in the millions. With over 60 years’ experience designing, engineering and fabricating, high-speed overhead conveyor systems for mission-critical interlogistics operations, Ferag has now secured a strong presence in the UK intralogistics market by winning three new contracts for solutions in the apparel and retail sectors.

Heading up Ferag’s UK operations, Darcy de Thierry, Managing Director, Ferag UK Ltd, says: “British retailers and manufacturers are experiencing huge structural change. The growing focus for most is on ecommerce orders, which places a heavy emphasis on high-performance fulfilment operations capable of handling thousands upon thousands of single or few-item orders a day.

“Automated systems, such as overhead pouch and sortation solutions, facilitate fast picking, making them increasingly critical to maintaining and growing order volumes. But businesses cannot afford for them to fail – they need well engineered solutions using only the best, hard-wearing components and low-friction materials. That’s where Ferag’s extensive experience within the newspaper industry – where reliability is paramount – will be a tremendous advantage to the UK market.”

Principle products in Ferag’s extensive range of innovative sorters and conveyors include: Skyfall, an overhead pouch system that combines conveying, buffering, sorting and consolidating, suited to a wide variety of goods weighing up to 20kg. The solution makes efficient use of available overhead space; Denisort, a tilt-tray sorter that provides order picking, conveying and sorting in one seamless and scalable solution; Denisort Compact, a modular vertical sorter designed for items weighing up to 12kg; Deniway, a plate chain conveyor with low-friction rollers for long conveying distances, offering smooth transfers with the minimum number of drive units; and Easychain, a largely maintenance-free continuous and seamless conveying system with an ultra-narrow curve radii, making it well suited to complex, 3D layouts.

Ferag has installed intelligent conveyor and sortation systems for some of the world’s largest brands, such as: DHL, Auchan, Nestle, Zeiss, Cewe, Zalando, Mayoral, Viapost, Peerless Clothing International, Dumoulin, AstraZeneca, Stage, VW, Shoebox, along with many more.

The launch into the UK’s intralogistics market plays to the strengths of Ferag’s international maintenance and support network, where remote and condition monitoring are provided 24/7 and replacement components are readily available to a UK based nationwide team of service engineers.

Ferag AG employs around 550 people worldwide and is represented in more than 18 countries with its own sales and service companies. The business has installed over 3,000 systems on five continents and holds in excess of 9,000 registered patents.

Conveying the right solution

Japanese engineering specialist Itoh Denki believes it can help integrators and OEMs looking to find intralogistics conveying solutions for the new economy. Logistics Business magazine editor Paul Hamblin reports.

In a logistics world in which there needs to be room for businesses of all shapes and sizes, it follows that the conventional logistics model needs to be challenged. Yes, the big players will still need their large Build-to-Suit warehouses, and vast, multi-tenanted logistics parks are undoubtedly here to stay. But what about ecommerce providers looking for professional, fast logistics?

These companies might be small – but they might grow very fast, in which case they need agility, flexibility. Most of all, they want ease of payment alongside ease of use. Not for them the vast capital expenditures on logistics of those giants who can make such facilities so cost-effective. Ideally, they want state-of-the-art logistics capability without necessarily needing the building asset that goes with it.

Japanese-founded engineering specialist Itoh Denki, which has worked with integrators and OEMs in logistics for many decades in the supply of rollers and conveying components, has recognised this pattern. It has identified a trend, notably in Japan where land use is at a premium, but increasingly in Europe, for multi-storey, multi-tenanted logistics spaces deployed with a pay-per-use sharing model.

“Think of it as Hotel Logistics,” quips Tatsuya (Ted) Akashi, Itoh Denki MD Europe. “You come and go as agreed, you can stay for longer if you wish and you only pay for those times.”

Recognising that reliable, flexible sortation is key to this business model, Itoh Denki has brought its Diverter-Centric Sorting to the market. Best known for Motorised Driver Roller (MDR) technology, Itoh Denki’s footprint in Europe has now expanded to include a fully capable Amsterdam Tech Centre to complement its base in St Pierre, France where the MDRs are given final assembly.

Alexander Gigerl, Technical Sales Manager, explains the Diverter-Centric sorting business case by pointing out that the high throughput of the traditional crossbelt sorter comes with a correspondingly high cost. He says that Itoh Denki’s F-RAT (Flat Right Angle Transfer) will bring down those costs dramatically, but without necessarily the very high throughputs some customers require. The company’s MABS (Multi Angle Ball Sorter) also brings with it considerable cost savings versus the cross belt but with three times the throughput of the FRAT. The combination means that Itoh Denki can offer a powerful hybrid solution to suit a variety of budgets and requirements.

An enormous variety of package sizes can be smoothly transported, even the most fragile loads. The list of benefits includes the flexibility and scalability that comes from a fully modular system. Maintenance and service is another plus, because faults can be sourced and fixed quickly via this modularity, without unnecessary and profit-killing downtime. Safety and comfort of workers is promised by the optimised footprint of the layout and the super-quiet, no pneumatics, 24v DC power source.

It is fully CE compliant, which means costs will not be incurred in installing extra safety facilities or barriers in the vicinity. Energy efficiency is assured by on-demand operation, the motor driven only when a load enters the zone.

The central 90° technology of the F-RAT offers the benefit of transfer without changing levels. Meanwhile, the MABS solution offers 30, 45 and 90° transfer.

Itoh Denki emphasises that it will not be selling direct to end users and will continue to work with its established OEM partners to ensure end user customer delight.

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