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Vaishali Ravi
January 23, 2025

It would be ideal if all product returns came back wrapped in their original packaging—but unfortunately, that’s rarely the case. Many of your returned items will be “open box” items, whether that simply means they’ve been removed from their packaging, or that they’ve already seen moderate or significant use before the customer chose to send them back.
As a merchant, it’s important to put return policies in place that are adapted for the not-so-pretty reality of how customers return products. Let’s take a look at how retailers manage open box returns, and what you can do to create customer-friendly policies that still protect your profit margins.
What are open box returns?
Open box returns are exactly what they sound like: Returns in which the customer has opened the box or packaging, and then decided to return the item.
That may happen for any reason, including products that are defective or don’t work as advertised. Often, there’s nothing wrong with the item—the customer simply decided they didn’t want it after all, or they preferred a different size, style, or model.
Open box returns may be in brand-new condition, or they may show signs of use. They may function perfectly, or they may have been sent back due to technical issues. But in any case, it’s unlikely that you’ll be able to resell the product for its original retail value after it’s been returned as an open box item.
That means it’s important to build customized return policies that account for the likelihood of receiving open box items.
What happens to open box returns?
If a returned product is still in its original packaging, you’ll be able to simply return it to your warehouse shelves for restocking and resale. But if the product is an “open box” item, it’s important to inspect the product for damage and defects, and determine whether it works as intended.
If the item has no issues, you’ll be able to restock and resell the product as an “open box” item, typically for a discount of around 20%. If it does have defects or problems, you may need to resell the item to a third-party liquidator or refurbishment company, where they’ll be able to fix up the item and resell it for a profit. Or, in the worst case scenario, an open box purchase may no longer be in resale condition under any circumstances, and may need to be disposed of.
In most cases, open box items won’t allow you to recoup the full value of the original purchase price—so how should you account for that in your returns policy?
How to handle open box returns
There are many ways to handle open box returns, and each retailer’s decision will come down to how they balance delivering a great customer experience against protecting their profit margins.
Let’s take a look at some common forms of returns policies for open box items:
Optimizing costs on open box returns
However stringent your policies around open box returns are, you have opportunities to protect your brand’s profit margins in managing reverse logistics.
Here are a few ways to handle open box returns sustainably:
With the right strategy in place for managing open box returns, you’ll be able to build your brand sustainably and boost customer retention.
Ready to build a best-in-class returns program? Book a demo of Loop today.
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