Returns Handling
Automation.
Built for the messiest workflows in the warehouse
Returns are no longer an exception.
They are a constant, high-volume operational load. Yet most warehouses still handle them manually. Inspection is slow. Decisions vary. Backlogs appear during peaks. Costs scale with headcount, not throughput.
Sereact automates returns handling with a dual-arm robotic station powered by Cortex. The system inspects, classifies, and sorts returned items while continuously learning from live production.
Why returns are still manual
Returns break traditional automation assumptions.
Returned items arrive:
in unknown orientations
mixed together in bins or totes
in inconsistent condition, from unopened to damaged
without reliable signals for resale or discard
Classic pick-and-place robots expect short, clean tasks.
Returns are long, messy processes.
So warehouses fall back to people.
What the Sereact system does
Sereact provides a complete returns handling station for real warehouse conditions.
Each return is treated as a multi-step process, not a single pick.
The system:
isolates individual items from mixed returns
manipulates items using coordinated dual-arm actions
inspects condition and completeness using vision
classifies items based on your policy
places items into the correct downstream flow
No pre-sorting. No special packaging. No ideal inputs.
Why dual-arm is essential
Returns handling requires control, not speed alone.
Items must be:
stabilised during inspection
rotated to expose damage or seals
regrasped when the first attempt is suboptimal
recovered when something slips or jams
Single-arm robots abort when something goes wrong.
Humans adjust and continue.
Sereact's dual-arm setup enables the same behaviour:
holding and inspecting simultaneously
controlled regrasping
recovery instead of failure
This is the difference between moving objects and handling returns.
Cortex.
Learning in production
Returns handling is a long-horizon task.
Success is not just "item picked". It is correct inspection, correct decision, correct placement.
With Cortex, the system observes the entire process:
visual ambiguity during inspection
force and contact during manipulation
early signs of instability
recovery actions and retries
Instead of learning only from final success or failure, Cortex evaluates execution quality continuously.
As a result, the system improves in live operation:
more stable grasps
fewer unnecessary retries
earlier recovery decisions
smoother multi-step handling
Learning happens on real returns, not staged data.
What this changes operationally
Returns handling shifts from a cost sink to a controlled workflow.
Automation enables:
consistent inspection criteria across shifts
lower per-item handling cost
safer handling of unpleasant or hazardous items
reliable sorting for resale, refurbishment, or discard
Items that were previously written off can be processed economically again.
Designed for live warehouses
This is not a lab system.
Runs continuously across shifts
Handles variation without pre-conditioning
Integrates into existing warehouse flows
Keeps humans in the loop where judgment is required
The robot does the repetitive, error-prone work.
Your team focuses on exceptions and decisions.
Fleet-level refinement in production
Returns handling is one of the most variable workflows in a warehouse. Across sites, shifts, and seasons, the same return can look very different. Packaging, condition, orientation, and completeness all vary.
Sereact handles these cases reliably in production today.
At the fleet level, Cortex aggregates execution data across deployed systems to refine inspection, manipulation, and recovery policies within defined operational boundaries. This refinement happens without changing customer workflows or introducing instability on site.
Each system runs within validated parameters. Fleet-wide improvements are rolled out deliberately, not experimentally.
The result is consistent returns handling across sites, with controlled, incremental gains in efficiency and stability over time.
What this
enables next
The same capabilities extend to:
kitting and recombination
refurbishment workflows
stateful manufacturing tasks
Returns handling is the entry point to process-level robotic reasoning.
Is this relevant for you?
This system is designed for operations where:
returns volumes are high and growing
manual inspection limits throughput
consistency and safety matter
write-offs are no longer acceptable
If returns are slowing your warehouse down, this is worth a conversation.
See it in operation
We'll walk you through the system, real deployments, and how it fits into your returns flow.