A warehouse employee stands in a sea of cardboard boxes, some of them open. The employee, who wears a bright orange high-visibility vest and rubber gloves, is opening one of the boxes while glancing at a piece of paper in her hand.
AI can help businesses ease the flood of online returns by streamlining the returns process and keeping customers informed before they buy. — Getty Images/Luis Alvarez

Why it matters:

  • Total merchandise returns are expected to have reached $890 billion in 2024, according to the National Retail Federation (NRF).
  • Losses due to return fraud totaled $101 billion last year, according to the NRF.
  • Merchants are increasingly tapping artificial intelligence to mitigate the high cost of product returns in a variety of ways: They’re using AI to make more detailed product descriptions and sizing information readily available to shoppers before they make their purchase, and they’re optimizing return logistics via the tech to determine the most economical ways to get items back to a store or warehouse, for example.

Merchants are wrestling with the ever-increasing challenge of product returns, seeking to staunch the flow of such items and minimize the costs of processing them, while at the same time ensuring a seamless returns process for their most loyal customers.

Total returns are projected to reach $890 billion in 2024, according to a report from the National Retail Federation.

Now artificial intelligence and machine learning are helping merchants throughout the pre- and post-purchase processes. These solutions not only seek to ensure that customers buy the right size and fit when it comes to shoes and apparel, for example, but also help implement customized return policies based on customer profiles.

Minimizing the volume of returns is just one aspect of the challenge, however. Merchants are also leveraging AI and machine learning to optimize the return process itself and identify whether returned products are best resold, donated, or discarded, or whether it might be more economical to let the customer keep the item.

These solutions are being implemented amid an increasing volume of fraud related to product returns, particularly among online purchases, and merchants are also deploying AI and machine-learning solutions that seek to reduce these instances of fraud.

“By embracing AI, retailers can create a more seamless, efficient, and tailored shopping experience in order to drive customer loyalty and boost sales,” returns solutions provider ReturnPro said in the 2024 Holiday Edition of its Returns Report. “As some retailers lean into discovering new ways to improve their returns, there is still significant whitespace for the continued adoption of these technologies.”

The report found that many merchants are deploying AI and machine-learning solutions to minimize product returns, including 36% that analyze customers’ purchase and return history to predict if they are likely to return items, 39% that identify products with high return rates and the reasons why they are often returned, and 25% that use programs to help determine accurate clothing sizes.

Preempting returns by leveraging AI to ensure a good apparel fit

One of the biggest areas of opportunity to minimize product returns is in helping customers make the right choices before they buy an item online. This is especially true for apparel and footwear, categories in which sizing and fit can vary by brand.

Retailers are increasingly analyzing data from past purchases to generate AI-automated suggestions for product sizes that are most likely to fit individual customers. Virtual try-ons, which lets consumers digitally try on everything from lipstick to loungewear before buying, are another tool that apparel merchants use to optimize product selection.

“I would say preventing returns up front is probably the easiest place to deploy AI, and where we're seeing merchants use it the most,” said Kristen Kelly, VP of Product at Loop Returns.

She estimated that more than half of the merchants that use Loop Returns’ solutions are using some type of fit or sizing tool to help their customers make the right selection before they complete their purchase.

AI not only helps retailers use data from customers’ past purchases, but it can also be used to flag specific items that are most likely to be returned, said Robert Johnson, Executive VP at ReturnPro.

[Read more: Inside Google’s Bold Push to Help Small Businesses Sell More Online Via the Magic of Generative AI]

I would say preventing returns up front is probably the easiest place to deploy AI, and where we're seeing merchants use it the most.

Kristen Kelly, VP of Product at Loop Returns

Identifying trusted customers

These return-prevention tools all start with the ability to identify the customer and thus determine their propensity to return certain purchases based on past behavior.

It’s important for retailers to balance the need to drive customer satisfaction against the cost of handling a return. Optimizing the returns process for customers considered “trusted,” based on factors such as past purchase history, return frequency, and reason for returning merchandise, is one way retailers are doing this, said ReturnPro’s Johnson.

These valued customers can be given incentives to complete their purchase by including assurances that product returns will be easy to execute, he said. AI can help merchants streamline this process by leveraging purchase history data and prompting effective responses.

“It’s about understanding past purchases, and what has been kept and what has been returned, and then being able to recommend something,” Johnson said. “We’re absolutely seeing AI being used from pre-purchase all the way to post-purchase as well.”

Walmart is among the companies on the leading edge of this technology, he said. The retailer has leveraged its vast trove of data to create trusted customer profiles and reduce returns.

In fact, nearly half (47.4%) of retailers surveyed said they have used AI to make more detailed product descriptions and sizing information readily available to shoppers before they make their purchase, according to the ReturnPro report.

Fraud prevention begins during the buying process: ‘AI can flag those specific high-risk customers’

Losses due to return fraud totaled $101 billion last year, according to the NRF, which found that 13.7% of all returns were impacted by fraud. More than half (52%) of retailers said they are implementing one or more preventative measures.

In fact, fraud prevention has emerged a key area where retailers are deploying AI solutions to mitigate the cost of returns, said Zack Hamilton, Head of Growth Strategy and Enablement at parcelLab.

AI can be used to detect customers engaging in specific behaviors associated with fraud, he explained. AI can help sift through the data to generate an appropriate return policy for each individual customer.

“You can start to flag those specific high-risk customers and put them under a specific review for suspected fraud returners versus someone who has been very loyal to your brand and rarely returns anything,” Hamilton said.

For those loyal customers, the return policy might be a little more lenient, he said.

“It’s leveraging AI to identify patterns in order to really drive a more personalized experience,” said Hamilton.

Kelly of Loop agrees that AI can be used at the time a customer is initiating a return and flag returns that may be fraudulent, such as if a customer may be returning an empty box or swapping the label from an authentic product to another item.

Detecting specific behaviors can help merchants make changes in the return process in real time, such as switching over to manual processing of the return so that they don't issue a refund until they actually have the item in hand and they've inspected it, she explained. Merchants can also limit fraudulent returns by only offering store credit, for example, rather than a refund.

Optimizing return logistics and resale opportunities via AI

Another key area where retailers are using AI to minimize the cost of returns is through the optimization of return logistics, helping determine the most economical ways to get products back to the store or warehouse.

Merchants are looking for ways to minimize the costs of processing their returns, and at the same time seeking to optimize the potential revenues they can obtain from reselling them. They can use AI to help determine if items can be returned to their original shelves, if they can be donated to charity, or if it makes more sense to dispose of them or let the customer keep them.

For example, merchants should be able to analyze their return data to determine how often products that are returned within a week are able to be resold or how often the products are returned damaged.

“Making a prediction up front about whether it’s worth getting that item back or not is critical,” said Kelly.

If merchants can predict that an item is likely to come back damaged or too late to resell, or if it’s just going to be too costly to process it, then they can just allow the customer to keep the item and eliminate the processing costs.

A key opportunity for minimizing the costs of product returns lies in routing the products to the right location, based on machine learning, said Kelly. Products are often reshipped after they have been returned, which adds to merchants’ costs, she explained. If more products are returned directly to the most efficient destination—a specific store, warehouse, or other destination—it can significantly reduce processing costs.

Johnson of ReturnPro agreed that resale of returned products should be a key objective for merchants. ReturnPro leverages AI to perform several functions that help its merchant partners optimize the potential revenues from product resales and minimize the costs of returns.

“We don’t even need humans to do it anymore, and that provides speed to get [returned products] back to the market,” he said.

CO— aims to bring you inspiration from leading respected experts. However, before making any business decision, you should consult a professional who can advise you based on your individual situation.

CO—is committed to helping you start, run and grow your small business. Learn more about the benefits of small business membership in the U.S. Chamber of Commerce, here.

Published