UNITED KINGDOM / AGILITYPR.NEWS / February 11, 2026 / As UK retailers continue to grapple with high return rates, Midland Pallet Trucks - a leading retailer of high quality pallet trucks, stacker trucks and lift tables - is warning that returns operations are accelerating wear and tear on warehouse equipment, particularly pallet trucks, in ways many businesses underestimate.

With online retail normalising free and fast returns, warehouses are handling growing volumes of mixed, damaged and irregular loads. Unlike outbound picking, which is typically planned around predictable pallet sizes and flow paths, returns handling is often improvised, congested and physically harsher on equipment.

“Returns don’t move through a warehouse in neat, uniform ways,” said Phil Chesworth, Managing Director at Midland Pallet Trucks. “They’re heavier in some cases, poorly wrapped, or partially palletised, and they’re often moved multiple times before being processed. All that places extra strain on pallet trucks that weren’t designed for chaotic movement patterns.”

Midland Pallet Trucks points to poor reverse logistics layouts as a major contributor to premature equipment failure. Returns areas are frequently squeezed into leftover space, forcing pallet trucks to operate in tight corners, over uneven floors and around temporary storage zones. This increases the likelihood of impacts, misalignment and accelerated component fatigue.

In many warehouses, returns also mean more manual repositioning. Pallet trucks are used for short, repetitive movements rather than long, straight runs - increasing stress on wheels, forks and hydraulic systems. When combined with higher-than-expected throughput during peak return periods, this can shorten service intervals and thus equipment lifespan.

“Businesses often focus on the labour cost of returns, but they overlook what it’s doing to their assets,” Chesworth added. “If pallet trucks are breaking down more often, that’s not bad luck: it’s a signal that the operation hasn’t adapted to how returns are actually handled on the floor.”

The issue is compounded when ageing or entry-level equipment is repurposed for returns handling without adjustment. Trucks already nearing the end of their working life are often pushed into the most demanding part of the warehouse, leading to breakdowns that disrupt both inbound and outbound workflows. Better zoning, clearer flow paths and equipment specified for heavier, inconsistent loads can reduce damage and improve uptime.

“Returns are here to stay, and they need to be treated as a core operation,” said Chesworth. “Ignoring their impact on equipment is a false economy. The real cost shows up later in downtime, repairs and replacement.”

For more information, visit https://www.midlandpallettrucks.com.