📝 TL;DR
🧠 Overview
A new AI system is being tested to catch fake or abusive returns as holiday return season surges. A major returns logistics company reports that U S retailers lose tens of billions of dollars each year to return fraud, with almost 16 percent of total retail sales coming back as returns and around 9 percent of those believed to be fraudulent.
To fight that, they have built an AI tool that screens returns in real time, looking for suspicious patterns before the money goes back to the customer. Big brands are already piloting it across thousands of physical drop off locations.
📜 The Announcement
A new report highlights that a UPS owned returns service has launched an AI system to flag suspicious returns at scale during the 2025 holiday season. The company handles box free, in store returns for online brands at thousands of locations and has seen how often fraud slips through when refunds are issued quickly.
The AI tool is currently being tested with well known fashion and sportswear brands while retailers process an estimated eight hundred fifty billion dollars worth of returns this year. The goal is simple, reduce the roughly seventy six and a half billion dollars lost annually to return fraud without making honest customers feel punished.
⚙️ How It Works
• Pattern spotting - The AI scans return requests from the moment they are started online, looking at timing, frequency, locations, order history and product details.
• Risk scoring - Each return is given a risk score, most sail through automatically, but higher risk returns are flagged for extra checks before the refund is approved.
• Network wide view - Because the system sits across thousands of drop off points, it can spot people trying similar tricks at different locations or across multiple brands.
• Item verification - Returns go through physical inspection at partner counters, while the AI helps decide which ones need closer review or audits.
• Evolving fraud tactics - The system is trained to detect lookalike products, swapped items and other subtle scams that humans might miss in a rush.
• Feedback loop - Every confirmed fraud or false alarm feeds back into the model, improving what gets flagged over time.
💡 Why This Matters
• Fraud is built into your prices - When retailers lose billions to fake refunds, those costs end up baked into prices, tighter fraud controls can help reduce waste and keep margins healthier.
• Honest customers may face more friction - AI checks could mean more questions or delays for some returns, even when you did nothing wrong, which puts a premium on clear communication and fair policies.
• AI moves deeper into customer service - This is another example of AI stepping into everyday touchpoints like returns, refunds and support, not just flashy chatbots.
• Data becomes a trust issue - The system relies on detailed behavioral data about shoppers, which raises questions about transparency, accuracy and how that data is stored and used.
• False positives could hurt loyalty - If the AI flags a genuine customer as suspicious, you risk damaging trust and pushing them to a competitor, so safeguards and human review matter.
🏢 What This Means for Businesses
• Factor fraud into your AI strategy - If you sell physical products, AI based fraud detection is becoming a practical tool to protect margins without hiring huge manual review teams.
• Design a human friendly return policy - Combine AI checks with clear messaging, fast handling for low risk customers and obvious paths to appeal decisions if something looks wrong.
• Keep your data clean and connected - These systems work best when order data, customer history and inventory are accurate and synced, which is a reminder to tidy up your backend systems.
• Communicate the why, not just the what - Let customers know you use smart tools to protect against abuse so you can keep generous return policies for everyone else.
• For non retail businesses, learn the pattern - Even if you do not handle returns, the same pattern applies elsewhere, use AI to flag risk quietly in the background while keeping the visible experience simple and friendly.
🔚 The Bottom Line
AI is becoming the silent partner behind the refunds button, deciding which returns are safe to approve and which deserve a closer look. For consumers, that means more invisible scoring happening behind the scenes.
For businesses, it is a clear signal that protecting margins in an AI era is less about saying no and more about using smarter tools to say yes to the right people faster.
💬 Your Take
If you knew an AI system was scoring your returns before approving your refund, would that make you feel safer that others are not gaming the system, or more worried about being wrongly flagged, and if you run a business, would you be comfortable putting AI in charge of these decisions?