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What do returns really cost you?

Updated 30 October 2026.

The short version

A return costs you twice, once in the money you spend handling it and again in the profit on the sale that went away. Put your own figures in below. The numbers already there are an example we made up, so please don't take them as a benchmark.

Handling returns costs you, per year£450,000

Gross profit lost on refunded orders, per year£840,000

Handling cost as a share of the profit you keep18%

Each point off your return rate is worth, per year£51,600

Treats each returned order as fully refunded, and assumes a kept order earns its full margin. Before any benefits you give, software fees or marketing costs.

How the sum works

Take the example above: 10,000 orders a month at £80, a 35% margin, a quarter of orders returned and £15 to handle each one.

We should be straight about that last figure, as it flatters the idea. It assumes the customer who no longer returns is the same one who would have bought anyway, and that won't always be so. A policy that puts people off buying can lower your return rate and your profit at the same time, and you won't see it unless you've kept a control group.

What goes in the handling cost

ZigZag estimates £10 to £20 per return, including logistics, repackaging and lost sales. It's a rough range from a returns company, and it includes lost sales (which the calculator counts separately), so your own figure will be better. From your books, add up:

Most finance teams know the first of these and guess the rest. An hour with whoever runs your warehouse will get you closer than any report, including this one.

What to do with the number

Put it next to your marketing budget, because we suspect few brands have ever seen the two side by side, and it can be an uncomfortable moment. Then break it down, since a few styles and a few customers will probably account for far more than their share. Measure the rate properly, find out why the items came back, and only then decide whether to charge.

Want this read against your store?

Send us your store address and we'll write you a short assessment of your returns policy and reviews, with one thing to test. It's free. We are also selecting three brands for a fee-free 60-day pilot.

Assess your returns

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