UNITED KINGDOM / AGILITYPR.NEWS / January 19, 2026 / Pallet Trucks UK is urging retailers and logistics operators to rethink how they handle returns, as what was once a post-Christmas headache has become a permanent operational challenge.

With free returns now an expected part of online shopping, alongside mid-season sales, promotions and next-day delivery promises, reverse logistics is placing huge pressure on warehouse space, labour and manual handling processes all year round.

Returns volumes are no longer confined to January. Fashion cycles, flash sales and customer-friendly policies mean stock is flowing back into warehouses continuously, often unpredictably. Unlike outbound fulfilment, returns require inspection, sorting and reallocation, adding extra handling steps and disrupting established pallet flows. Many warehouses are struggling to adapt layouts and equipment to cope with this constant back-and-forth movement.

In practical terms, rising return volumes are reshaping how warehouses operate. Temporary holding areas for returned goods are becoming permanent fixtures, aisles are seeing more cross-traffic, and pallet trucks are being used more intensively for shorter, more frequent moves. Without reliable handling equipment designed for this kind of stop-start workflow, such as pallet trucks, stackers and lift tables, bottlenecks can quickly form - slowing down both returns processing and outbound orders.

Manual handling pressure is also increasing. Returns often arrive mixed, damaged or loosely packed, requiring more manoeuvring and repositioning than standard palletised goods. Pallet Trucks UK warns that relying on worn or unsuitable pallet trucks in these conditions raises the risk of operator fatigue, minor injuries and delays that ripple through the wider operation.

Phil Chesworth, Managing Director at Pallet Trucks UK, said, “Returns used to be treated as a seasonal inconvenience. Now they’re a core part of retail logistics, and warehouses need to be set up accordingly. If your equipment and layout are still designed around one-way pallet flow, returns will constantly get in the way.

“We’re seeing businesses rethink how they use pallet trucks to create more flexible handling zones and keep stock moving smoothly in both directions. Robust, easy-to-control equipment helps teams deal with unpredictable volumes without slowing everything else down. That’s becoming essential as returns continue to grow.”

Addressing returns as a year-round reality, rather than an afterthought, is key to maintaining efficiency and protecting staff wellbeing.

For more information, please visit: www.pallettrucksuk.co.uk.