Signed, sealed, returned?

Packaging Solutions

We all know first impressions matter, but what happens if it is not love at first sight between the consumer and your product?

A number of packaging solutions are available that simplify the returns process and make for happier customers. Many will be on show at the returning Packaging Innovations & Empack.

As e-commerce has boomed, so the amount of products being shipped directly to consumers has skyrocketed. At the same time, this has resulted in the amount of returns substantially increasing.

While there are ways and means that have been around for a long time to return products to a retailer, these are often out of step with consumers purchasing from small and independent retailers through platforms such as Etsy, TikTok Shop, Shein, Temu, and, of course, Amazon.

Without a physical location to return goods to, consumers are left needing to find an appropriately sized and sturdy shipping box or mailing bag that can be relabelled and reused.

Knowing this challenge is causing a headache for consumers, the packaging supply chain has developed myriad solutions to simplify returns and improve engagement with consumers. Many will demonstrated during Packaging Innovations & Empack 2026 on 11 and 12 February, 2026.

(Re)-commerce

The e-commerce spike has resulted in a drive to introduce packaging solutions that natively facilitate the returns process.

Yorkshire Packaging Systems (S100) includes return closing strips on its poly bags and mailing bags for e-commerce and order fulfilment. These are offered as a value adding feature to bags, alongside easy tear perforations, handle holes, vent holes, and hang holes.

Rapisac from Carlton Packaging (H140) is hanging mailing bag system created for quick and easy filling. The bag hangs from a patented desk edge mounted backplate to facilitate quick and easy hanging, as one handed opening and filling increases productivity; up to one hour per 1000 bags.

For returns, Rapisac can be created with a double seal tear strip, allowing consumers to repack their returns in the same mailing bag.

At the same time, Carlton Packaging offers Rapimailer as a 100% paper bag replacement for polythene courier or mailing bags. These 100% paper bags can completely replace single use plastic mailing bags, whilst being designed to offer greater protection than polythene due to the paper grades available. Rapimailer has a high strength closure seal, with a second closure seal able to be included in the design to provide a secure returnable solution.

V Star Packaging (L100) has a number of different kraft mailer solutions for different applications. This includes mailers with large gussets that allow for various sizes of items to be shipped.

Made from recyclable and biodegradable materials, V Star Packaging’s solutions have high tensile strength and toughness to ensure protection of products during transit. A second adhesive strip built into the mailer’s design allows consumers to easily and simply reuse the same packaging for returns.

Locked and loaded

The RapiReturn box, also from Carlton Packaging (H140), offers a similar capability for folding carton packaging. Instead of a tape to seal/reseal the box, it features an intuitive locking system suitable for both the initial shipment and the return journey back to the supplier, if needed.

Specifically, the RapiReturn box features a hammerhead style locking mechanism where the tabs fold over and push into locking slots, creating a secure, tamper evident seal. Once locked, the tabs unfold internally, preventing removal and providing a highly durable closure.

eReturn from Reedbut Group (J130) features a tape free double locking design that means only one box is required for dispatching and returning items, saving material and costs. This packaging solution streamlines the returns process for an improved customer experience. eReturn XL is designed for larger items using a tape free closure and secure locking side tabs to make returns easy and hassle free.

Rajapack UK (D82) offers quick pack returnable postal boxes that are designed to offer easy and fast assembly. For initial distribution, the boxes are assembled in as little as four seconds by pushing the opposite corners towards each other, which locks the base flaps together automatically. These strong and secure crash lock base boxes are closed with an adhesive strip so there is no need for tape or glue.

The boxes feature a tear strip that make them easy for consumer to open and also to reseal, using the second adhesive strip located behind the tear strip.

At the same time as making the returns process easy for consumers, brands and retailers must be conscious of fraud.

Hallmark Labels & Print (F134) has a range of bespoke branded ribbons that are designed to combat fraudulent returns to clothing and fashion brands.

To use, simply unroll the desired amount of ribbon, loop it visibly through a product and secure the ends with specialist security sticker. This sticker is designed to disintegrate when tampered with, preventing reattachment. Alternatively, the ends of the ribbon can be secured with a press stud or by sewing the sash into a seam for a permanent anti-return marker that remains conspicuous and tamper proof.

The use of ribbons discourages customers from wearing and returning items as new, which is a common challenge faced by both online and brick and mortar retailers, especially those offering premium goods.

As evidenced, all of these products and more are designed to make the lives of consumers easier at the same time as safeguarding the products and reputation of brands and retailers.

This makes them an important part of the Packaging Innovations & Empack 2026 experience for all brands and retailers attending the event at the NEC in Birmingham on 11 and 12 February, 2026.

The event is free to attend and you can register for your complimentary ticket here.