COSMIC : The Reverse Logistics Solution Powered by Intelligent Vision
Balea and Zebra have combined their expertise to automate the reading of non-barcoded product information on your returns.
faster
reliability
traceability
Rising customer returns, complex traceability, regulatory requirements (EPR), customer satisfaction :
returns management has become a major strategic and financial challenge for modern warehouses.
For every returned product, non-barcoded text data (lot numbers, expiration dates, anti-diversion codes, serial numbers, and more)
must be read, keyed in, and checked by hand, with direct consequences for productivity, traceability, and the customer experience.
The solution :
To meet these challenges, Balea and Zebra Technologies combined their expertise to create COSMIC :
An intelligent vision solution that uses artificial intelligence to automate the reading and validation of text-based product information.
More than a simple tool : reverse logistics software that integrates with your existing flows to optimize performance and cut costs.
Reverse Logistics: A Fast-Growing Strategic Priority
Reverse logistics refers to all the flows that move upstream through the supply chain, from downstream back to the source :
customer returns, supplier returns, defective products, and recalls.
Long seen as a secondary cost center, it has become a major strategic priority.
A Market Worth Over USD 1.3 Trillion
The global reverse logistics market is worth more than USD 1.3 trillion in 2025 and is expected to quadruple by 2035 (Future Market Insights).
In retail alone, nearly 17% of sales are returned (National Retail Federation × Happy Returns), driving rising costs and complexity for every player in the chain.
Why Automate Product Returns Management ?
Traditionally, returns processing relies on manual data entry: an operator picks up the product, reads the information on the packaging (sometimes with a magnifying lamp), then keys it into the system. Faded labels, angled codes, tiny characters on cosmetics packaging: all of these are barriers to operational efficiency that slow processing, multiply errors, and weaken returns traceability.
For truly effective returns flow management, product data capture must be automated from the moment of receipt. Returns flow optimization begins where manual data entry ends. That is exactly the bottleneck COSMIC removes.
COSMIC: The Balea × Zebra Intelligent Vision Solution
An innovation born from the field
COSMIC grew out of a simple observation, seen every day in cosmetics fulfillment centers: the operators handling returned products had to read lot codes printed in tiny alphanumeric characters on the packaging, with a magnifying lamp as their only tool. The process was slow, uncertain, tedious, and tiring. From this real-world need came the idea of a camera-based reading station able to automatically capture every critical piece of information on a returned product in a single operation, eliminating manual errors and freeing up valuable time.
To take on this challenge, Balea partnered with Zebra Technologies. COSMIC combines an industrial Zebra CV60 camera (5 megapixels, 22 fps) with the Zebra Aurora software suite and its artificial intelligence engine (OCR model).
How it works
The operator presents the returned product under the camera of the COSMIC station. In a single pass and instantly, the system automatically identifies and captures all the critical data.
Watch the video
What Makes COSMIC Unique
The Benefits of COSMIC for Your Reverse Logistics
COSMIC delivers three key benefits to streamline your returns, improve your logistics processing, and strengthen your supply chain performance.
01
Dramatically Higher
Productivity and Reliability
- 3x faster processing than manual handling thanks to full automation of data capture and validation.
- 99.9% reliability in the automatic identification of key information (lot numbers, expiration dates, anti-diversion codes), drastically reducing human error.
- Human resources freed up : your teams focus on higher-value tasks (analysis, optimization, customer relations).
02
Complete Traceability
and EPR Compliance
- Centralized data : all product information is digitized, indexed, and searchable in seconds.
- Seamless collaboration : data is available in real time to every department (logistics, quality, customer service).
- EPR compliance assured : structured document management that meets Extended Producer Responsibility requirements and current environmental regulations.
03
Optimized Customer
Experience
- Simplified returns : faster refunds and exchanges through automated, reliable processing.
- Fewer disputes : accurate data reduces errors and improves transparency with the consumer.
- A stronger brand image : smooth, professional returns handling that enhances the brand and builds end-customer loyalty.
Bonus : built-in sustainability
Less paper, value recovery from returned products, and an active contribution to reducing your carbon footprint.
Ready to perfect the excellence of your logistics operations ?
Our experts are here to answer your questions.
They analyze your setup and propose the solution best suited to your flows, your constraints, and your performance objectives.
FAQ
COSMIC and Reverse Logistics
Find answers to the most frequently asked questions about our services, processes and support.
Need more? Our team is here to help.
Still have questions?
Our experts are here to support you at every step of your logistics transformation.
What is reverse logistics ?
Reverse logistics refers to all the flows that move upstream through the supply chain, from downstream back to the source: customer returns, supplier returns, defective products, recalls, and refurbishment.
Long seen as a secondary cost center, returns flow management has become a major strategic priority, with a global market worth more than USD 1.3 trillion in 2025 and expected to quadruple by 2035.
How can you optimize reverse flows in the warehouse ?
Reverse flow optimization rests on four levers: automating product data capture from the moment of receipt, streamlining sorting and quality control, guaranteeing complete lot-by-lot traceability, and using the data to identify the root causes of returns.
The key is to eliminate manual data entry, which remains the leading source of cost and defects in reverse logistics operations.
How can you reduce reverse logistics costs ?
Reducing the cost of returns management comes down to three areas:
- operational productivity (by automating low-value tasks),
- data reliability (every keying error creates a dispute, a stock loss, or a nonconformity),
- regulatory compliance (EPR, GMP, GDP), which can trigger penalties or hidden costs if poorly managed.
A reverse logistics software driven by intelligent vision, such as COSMIC.
Which sectors benefit most from COSMIC ?
The sectors where regulatory traceability is critical and return volumes are significant:
- cosmetics and pharmaceuticals first,
- manufacturing,
- electronics, retail,
- e-commerce,
- FMCG, food and beverage,
- third-party logistics (3PL) providers.
Does COSMIC require any configuration or setup ?
No. COSMIC is a plug and play solution, operational from day one. No lengthy learning phase and no upfront setup of the product master data.
Can COSMIC integrate with an existing WMS or ERP ?
Yes. The data captured by COSMIC is made available to your IT environment.
During a tailored assessment, our teams work with you to define the integration scope best suited to your organization.