Hidden footprints in reverse logistics: The environmental impact of apparel returns and carbon emission assessment

The rising volume of apparel returns, driven by e-commerce, presents a significant environmental burden. This study provides a granular assessment of this impact by quantifying the carbon footprint of apparel returns in the United States, focusing on emissions from transportation, packaging, and disposal. We employ a robust mixed-method approach, integrating Life Cycle Assessment (LCA) with detailed emission coefficient models to analyze proprietary logistics data from two major U.S. apparel retailers (2019–2021). Our analysis reveals that transportation is the dominant emission source, accounting for over 90% of the total carbon footprint in some cases. Specifically, we find that logistical network design is a critical determinant of environmental impact. For a retailer with a centralized return system, returns traveling over 1000 miles generated 29,143 t of CO2 in 2021, representing 91% of its total return-related transport emissions. In contrast, a retailer with a decentralized network saw long-distance returns contribute a lower, yet still substantial, 6686 t (64% of its total). Packaging constitutes a secondary but important emission source, contributing approximately 1100–1750 t annually per retailer. These findings demonstrate that optimizing reverse logistics networks through decentralization and adopting sustainable packaging are critical, actionable strategies for mitigating the environmental harm of apparel returns. This research provides essential, data-driven insights for retailers and policymakers aiming to build a more sustainable apparel sector.