A Full-Process Carbon Footprint Assessment of Online and Offline Apparel Sales: Integrating Return Logistics

This study develops a comprehensive carbon footprint assessment model that integrates forward and reverse logistics to evaluate and compare greenhouse gas emissions from online and offline apparel sales channels in China, with a particular focus on high return rates. The model quantifies emissions from transportation, packaging, storage, and operations, incorporating return and exchange logistics. The system boundary is limited to enterprise-controllable sales-phase activities and excludes consumer travel. Three sales models are compared: factory-to-consumer (F2C), traditional business-to-consumer (B2C) e-commerce, and brick-and-mortar retail (BMR). Within this defined boundary, BMR exhibits the lowest carbon footprint (0.296 kg CO2e/item), followed by F2C (0.408 kg CO2e/item) and B2C (0.602 kg CO2e/item). Packaging dominates online emissions (55–57%), whereas store operations are the main contributor to offline emissions (43%). Return rates are identified as a decisive factor, accounting for over 31% of e-commerce emissions and potentially increasing them by 171.3% under extreme scenarios. Sensitivity analysis reveals that trunk line distance (factory to warehouse) has a greater impact on emissions than last-mile return route optimization. Relocating the factory closer to consumers reduces B2C transport emissions by 72.3%, whereas replacing conventional packaging with recycled plastic reduces total B2C emissions by 46.0%. These findings provide channel-specific sustainability strategies: return reduction and packaging innovation for online channels, and energy efficiency improvements for physical stores. These results are conditional on the defined system boundary. If consumer travel by private car were included, the relative advantage of offline channels would diminish or could reverse.