Powering $2B Returns Operation With Integrations Delivered 75% Faster

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10 Systems, 15 Workflows, 75% Faster

As ZigZag Global scaled to manage over $2B in returns for leading retailers, integration delivery became a critical dependency. Delays or instability during peak return seasons could disrupt retailer operations and impact revenue at scale.

"Versori delivered results 75% faster than alternative platforms, while maintaining quality throughout the implementation."
Al Gerrie
CEO @ ZigZag Global
12+ Workflows

Deployed across their entire returns ecosystem, powering $2B in returns.

About

ZigZag Global is a SaaS platform that helps e-commerce retailers manage domestic and international returns.

Industry

Retail & Ecommerce

Company Size

51-200

Headquarters

London, United Kingdom

Systems Integrated

Executive Summary

75% reduction in custom connector development time, from 8 weeks to 2 weeks per integration.

12+ workflows deployed across their entire returns ecosystem.

10 complex embedded integrations, including Shopify, NetSuite, Klaviyo, Magento, Peoplevox, Gorgias, Brightpearl, Linnworks, Zonos, and Avalara.

100% platform stability during peak return seasons, when transaction volumes increase.

Project extension to build out full integration marketplace.

ZigZag Faced a New Kind of Threat: An Integration Layer That Could Not Keep Up

ZigZag Global helps e-commerce retailers manage returns by connecting them to a worldwide network of warehouses and carrier services.

With billions of dollars in returns flowing through its platform each year, the margin for error is thin. Any delay, data mismatch, or failed integration directly impacts retailer revenue, customer trust, and brand loyalty.

But as ZigZag scaled to support more retailers across more markets, they faced a new kind of threat: an integration layer that couldn’t keep up.

"Any failure during peak season would have cost retailers millions in lost revenue and broken trust."
Paul Dawson
Chief Product Officer

The Integration Challenge

Each return must navigate unique workflows, tax rules, refund calculations, exchange logic, inventory adjustments, customer communications, and multi-leg delivery routes.

As retailer demand increased and integration requirements became more bespoke, ZigZag’s internal teams were spending increasing time managing complex API connections. Each new retailer onboarding required custom work, slowing deployment and diverting engineering focus away from core product innovation.

With every retailer using different platforms, from legacy ERPs to modern e-commerce systems, the data structures, API protocols, and business logic vary dramatically.

ZigZag's growth was being constrained by four critical integration challenges:

Mounting Engineering Pressure: every new retailer introduced new integration requirements, the engineering team was increasingly consumed by integration work instead of product innovation.

Inconsistent Integration Capabilities: Traditional iPaaS struggled to handle the complexity that  ZigZag required, such as real-time tax calculations with Avalara, or multi-stage order workflows across Shopify.

Scalability Bottlenecks: Bespoke integration development slowed retailer onboarding, created backlogs and made it harder to close deals or expand into new markets.

Data Mapping Complexity: Mapping between different schemas, field names, and formats was highly manual. Minor discrepancies in API documentation could de-rail entire integrations.

“The core challenge was integration, and traditional iPaaS solutions couldn't handle the orchestration complexity we needed while maintaining the development speed our business required.”
Al Gerrie
CEO

Why ZigZag Chose Versori

ZigZag evaluated numerous integration platforms before selecting Versori.

ZigZag recognised that existing integration approaches would not scale with their growth ambitions. The team needed a solution that could standardise integration delivery, reduce engineering overhead, and ensure stability during peak trading periods.

With retailer demand rising and custom integrations consuming valuable engineering cycles, ZigZag’s leadership knew a new scalable approach was essential to future growth.

What set Versori apart was the combination of platform, methodology, and deep domain expertise.

Versori’s AI-native platform enabled ZigZag’s teams to design and deploy integrations dramatically faster. Instead of custom-coding every scenario, a series of LLMs (Large Language Models) orchestrated the build, and handled business logic changes, API connectivity, and error handling automatically.

The platform also abstracted protocol differences across systems:

Shopify (REST and Webhooks)

NetSuite (REST and SOAP)

Avalara (Specialized Tax APIs)

Warehouse Systems Using SFTP

All of these could be connected within the Versori platform.

Equally important was the partnership. Versori brought deep experience in e-commerce, ERP, logistics, and returns management. Where ZigZag’s team might spend days interpreting an unfamiliar API, Versori’s AI capabilities meant that the nuances would already be understood, dramatically accelerating delivery.

“Versori helped us research deeper, quicker, and start to streamline our “after returns” data workflows, making integration between ZigZag and 3rd party systems far more efficient.”
Paul Dawson
Chief Product Officer

How Versori delivered value

Addressing increased demand for connectors

By using Versori’s Plan agent, ZigZag transformed how connectors are built. What previously required extensive manual scoping and research can now be planned, documented, and structured from a single prompt.

Planning that once took significant engineering effort can now be completed in as little as 15 minutes per connector. This enables ZigZag to scale its integration ecosystem efficiently, reduce overhead, and support growth without increasing operational strain.

Handling complex workflows & data transformations

Versori’s AI agents autonomously orchestrate complex workflows, map and standardise data across platforms, and validate outputs in real time.

This ensures consistent, reliable data flow, enabling ZigZag to manage growing operational complexity while maintaining accuracy and performance as the business expands.

Avoiding delays caused by API changes

Manual API mappings often break as schemas evolve, creating delays and rework. Versori’s Connect Agent automatically detects schema drift, regenerates accurate mappings, and learns from corrections over time.

This accelerates integration triage and reduces disruption, ensuring systems remain stable, up to date, and performant as underlying APIs change.

Reducing engineering overhead

As transaction volumes increase, undetected errors can quickly escalate, driving up costs and diverting engineering focus.

Versori monitors transactions in real time, identifying and resolving issues before they compound. This reduces rework, prevents downstream failures, and lowers operational overhead allowing engineering teams to focus on innovation instead of firefighting.

Implementation

The rollout prioritised integrations by business impact. Core workflows, order processing, inventory synchronisation, and customer communication, launched first. More advanced capabilities, including tax compliance automation and cross-border coordination, were layered on top.

Every integration was built with robust error handling, monitoring, and performance optimisation to withstand peak-season volumes. All integrations were delivered as multi-tenant embedded connectors, enabling ZigZag’s customers to plug in and go, without custom development.

Where onboarding once took weeks of manual engineering effort, teams now move at pace, freeing development time for strategic innovation.

"Versori didn't just connect our systems, they transformed how we deliver value to retailers. What used to take 8 weeks now takes 2."
Paul Dawson
Chief Product Officer

Use Case Deep Dive: ZigZag > Linnworks

Unified Return Visibility: Channel Sync for Retailers

Managing returns across sales channels created visibility gaps and manual workload for retailers using Linnworks. Without real-time updates from ZigZag Global, return data was often delayed or inconsistent, leading to inaccurate stock levels and slower customer resolutions.

The solution:  Versori delivered a seamless integration between ZigZag Global and Linnworks that allows...

Post Returns: Automatically push return data from ZigZag into Linnworks, ensuring all returns are logged and processed in one central system.

InventoryTrack Returns: Keep Linnworks continuously updated with real-time return status changes,such as “In Transit,” “Received,” or “Refunded.” synchronisation to prevent overselling.

Integrations Delivered 75% Faster

ZigZag has strengthened its position as a trusted global returns partner to support even larger retailers and expand into new international markets.

What was once a growth constraint became a competitive advantage. ZigZag can confidently commit to aggressive timelines, close deals faster, and expand into new markets without fear of integration bottlenecks.

Retail partners benefit from autonomous data flow across their entire commerce ecosystem. Returns, exchanges, refunds, and communications run automatically, reducing recurring overhead costs, and transforming returns from a cost center into a loyalty driver.

By offloading integration complexity, ZigZag’s engineering team refocused on core innovation. New analytics capabilities, smarter warehouse algorithms, and advanced returns policy engines shipped faster, capabilities that would have stalled under the old integration model.

For a company processing billions in returns annually, Versori removed the fundamental barrier holding ZigZag back. The result: a scalable foundation that supports growth, experimentation, and industry leadership.

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