UNITED KINGDOM / AGILITYPR.NEWS / April 08, 2026 / Spring is here, and yet UK warehouses are continuing to feel the aftershocks of the post-Christmas returns surge. What was once considered a short-term January spike has, in recent years, evolved into a prolonged period of reverse logistics activity that is placing sustained pressure on warehouse capacity.

According to Midland Pallet Trucks, retailers may have underestimated just how long returns would dominate warehouse workflows. Instead of a quick reset after peak season, many distribution centres are now juggling incoming spring stock alongside a steady flow of returned goods that must be inspected, sorted and redistributed.

Unlike outbound fulfilment, returns handling is rarely a linear process. Items often move through multiple stages, from initial intake and quality checks to repackaging, restocking or disposal. Each step requires additional handling, increasing the number of times goods are moved across the warehouse floor.

This repeated movement is having a direct impact on equipment usage. Pallet trucks that would typically support straightforward inbound and outbound flows are now being used more intensively, often handling the same stock several times before it reaches its destination. The result is increased wear on equipment, as well as greater physical demand on operators.

Warehouse congestion is another growing concern. Returns processing areas can quickly become bottlenecks, particularly when space is already being allocated to new seasonal inventory. With more pallets circulating internally, maintaining clear pathways and efficient movement becomes increasingly challenging.

Phil Chesworth, Managing Director at Midland Pallet Trucks, said the scale and duration of returns activity is changing how warehouses operate. 

“The volume of returns isn’t just a January issue anymore,” he explained. “We’re seeing businesses still working through backlog well into March. That creates a very different environment on the warehouse floor, where goods are moving back and forth rather than simply flowing through.”

He added that reverse logistics places unique demands on both people and equipment. “Handling returns is often more labour-intensive and less predictable than outbound picking. Pallet trucks, stacker trucks and lift tables end up doing more work because items are handled multiple times. If equipment isn’t up to the task, it can slow everything down and add to the pressure on staff.”

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