Cross-border 2025: How to sell internationally without losing your margin (or your sanity)

The latest market data shows that as many as 59% of online shoppers in Europe regularly buy from foreign stores.
Forecasts are optimistic: by 2029, the value of the cross-border logistics market is set to exceed $200 billion.
This is not just a trend — it’s a real growth path for online stores that want to sell more, smarter, and at better margins.

But cross-border doesn’t forgive mistakes. Underestimated customs fees, VAT errors, or mishandled returns can swallow your margin faster than a Black Friday discount.
See how to get it right — before your customer buys… but not from you. Let’s dive in!

Cross-Border 2025 — still an option, or already a must?

Just a few years ago, selling abroad was the domain of big brands with huge budgets for marketing, integrations, and warehouses across multiple countries. Today, that advantage is fading fast. So, the question for 2025 is: can you really afford not to offer cross-border sales?

According to DHL eCommerce Insights, 59% of global shoppers already buy from stores outside their own country. In Europe, one in two consumers regularly checks foreign offers. And here’s what’s even more interesting: one in three buys from foreign stores every month — and it’s not just fashion or electronics. More and more, categories that rarely crossed borders before are now booming: organic products, supplements, home goods, and niche premium brands.

What’s driving this shift?

It’s not just about lower prices. What attracts buyers today is assortment — unique products they can’t find locally. A broader, more diverse selection (especially items they can’t buy at home) and global marketplaces that make it just a few clicks away. For stores, this means one thing: borders are no longer a barrier for business.

Forecasts don’t lie. The global cross-border e-commerce logistics market is expected to grow from $86 billion in 2024 to as much as $210 billion by 2029.
So, what about Poland? Poland is becoming Europe’s logistics hub, thanks to competitive costs, its strategic location, and improving infrastructure. Companies from Germany, Scandinavia, and the Benelux are increasingly choosing Poland for their warehouses and fulfillment centers.

What does this mean?

Cross-border is no longer an add-on — it’s becoming the core of your growth strategy. If you’re not thinking about export in 2025, you risk losing customers to competitors who treat the border as nothing more than paperwork.

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What Really Attracts Shoppers to Buy Internationally?

Why does someone in Berlin order a candle from Poland, or a shopper in Prague wait a week for a delivery from Spain when they could buy something similar locally? The answer isn’t obvious — cross-border is not just about price anymore.

According to research, 51% of buyers still say lower prices are the main reason to choose delivery from abroad. But right behind it comes something just as strong: a unique product range. Many buyers look for products they simply can’t get at home. They want higher quality, or they’re hunting for things they can’t find locally. Interestingly, this “hunt for uniqueness” is growing strongest among younger groups — Gen Z and millennials, who love brands outside the mainstream.

For an online store, this is both an opportunity and a challenge. Cross-border opens the door to customers willing to pay more for something special. But that enthusiasm quickly vanishes if hidden customs fees, confusing VAT, or high return costs show up at checkout.

These logistics and returns barriers are often why carts are abandoned. According to Pitney Bowes, 43% of customers worry about customs costs and 46% are discouraged by long delivery times. Add tricky returns to the mix, and even the best offer won’t reach the customer.

So, what’s the takeaway?

Price, availability, and uniqueness work in your favor. But all that value disappears if your cross-border logistics aren’t rock-solid. Predictable delivery, clear costs, and easy returns are now the bare minimum if you want loyal international customers.

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New barriers and rules: Why cross-border isn’t just packing boxes

Let’s finally ditch the romantic vision of cross-border sales — the idea that you just list a product, launch a campaign, and orders flood in from across Europe. The reality? It’s often tedious calculations, paperwork, and regulations that change faster than TikTok trends.

A recent example: the EU’s proposed €2 fee per package for low-value parcels (up to €150) from outside the EU. The goal? To curb the flood of cheap parcels from China. Sounds fair — but for store owners still shipping straight from Asia, it makes offering a competitive price harder than ever compared to brands that moved stock to local EU warehouses.

Start your e-Commerce in the EU

VAT in different EU countries

Don’t forget VAT. For the buyer, it’s often just a small note at checkout — but for an online store, especially one selling cross-border, it’s a maze of rules that can quietly stall growth.

Since 2021, any shop selling to consumers in other EU countries must apply the VAT rate of the buyer’s country (the destination principle). For small stores, this might sound like a formality — but in practice, without an OSS (One Stop Shop) or IOSS (Import One Stop Shop) system, you must register separately in each country where you sell more than €10,000 a year. To put this in perspective: the VAT on cosmetics is 19% in Germany and 23% in Ireland — so the wrong rate on an invoice can mean corrections, fines, and an unhappy customer waiting twice as long for delivery.

In 2023, many UK sellers who shipped to the EU without IOSS registration faced huge volumes of returns. Buyers often refused to accept packages when couriers asked for extra VAT and handling fees. As a result, products came back at the seller’s cost — often with import fees charged twice.

Don’t overlook the fine print. In Germany and France, marketplace checks are increasing. Amazon and eBay can suspend listings if sellers don’t have valid VAT numbers or local registrations. For big brands, that’s routine. For smaller stores, it’s a reason to hire an accountant — or partner with a fulfillment expert who handles it for you.

Returns: the silent margin killer

Another cost that’s often underestimated: returns. Shoppers in Germany, the Netherlands, or Scandinavia are used to free returns — and the seller covers the full logistics cost.

According to Statista, over 50% of German online shoppers returned at least one order in the past year. The average cost of handling a single cross-border return? €15–25 (including transport, handling, sorting, and restocking). On a €40 order, your margin vanishes instantly.

Big fashion players like Zalando or About You are testing paid returns, but mainly in their local markets. For smaller stores selling cross-border, a local return point or return warehouse is the standard. It saves you from shipping each item back to your main warehouse in Poland, which can cost more than the product itself.

Practical takeaway

If you’re planning cross-border sales, focusing only on the delivery price isn’t enough. You need a plan for:

Proper VAT compliance in different countries (OSS/IOSS)
Returns that meet local expectations (fast, low-cost, convenient for the customer)

Without this, your store can drown in costs before you build real sales abroad.

So, what does it mean?

Cross-border in 2025 isn’t just about asking “Should we sell abroad?” — it’s about asking “Where should we keep our stock so customs, VAT, and returns don’t eat us alive?”
Smart logistics starts with strategy — not with a shipping label. A trusted logistics partner who knows how to handle VAT and compliance can make all the difference.

What does a €50 parcel really cost? — China vs. local EU warehouse

Scenario:
A customer in Germany orders a product worth €50 from either:
– the seller’s warehouse in China, or
– a local EU warehouse (e.g., in Poland).

Cost Element Amount (€) Comment
Product price 50.00 Store price
Delivery cost (average) 8.00 Long shipping time (10–14 days)
€2 fee for non-EU parcel 2.00 New EU regulation
VAT (19% in Germany) 9.50 Often paid by the customer on delivery
Courier handling fee 5.00 Collecting VAT = customs handling cost
Total cost to customer 74.50 Final doorstep cost

Local EU Warehouse (Poland)

Cost Element Amount (€) Comment
Product price 50.00 Store price
Delivery cost (average) 6.00 Faster delivery (2–3 days)
VAT (19% in Germany) 9.50 Already included — no payment on delivery
€2 fee Not applicable — stock already in EU
Courier handling fee None — VAT settled via OSS/IOSS
Total cost to customer 65.50 Predictable, fast, no hidden surprises

Comparison:

Scenario Delivery Time Final Cost Risk of Extra Fees
China 10–14 days €74.50 High — VAT, fee, customs
Local EU Hub 2–3 days €65.50 Low — VAT settled upfront

Takeaway:

For the store:
Stocking goods in an EU warehouse means higher operating costs — but eliminates surprises for the customer, increases conversions, and reduces returns due to refused deliveries.

For the customer:
No hidden costs + faster delivery = greater willingness to buy and a lower chance of an abandoned cart.

Where should you store your stock? Cross-border logistics models in practice

Once you’ve defined the product range you want to sell, the target group you want to reach, and your store or marketplace plan — the next key question is: where should your inventory sit?

Cross-border logistics is not just boxes and labels — it’s the total cost: delivery time, returns, customs, VAT, and whether your customer will buy again. Let’s break down popular cross-border models:

Central warehouse — cheaper but slower

The most common model among Polish online stores is a central warehouse, usually located in Poland. Cost-wise, it’s attractive: low storage rates, lower labour costs, and cheap shipping to Germany or the Czech Republic.

But here’s the catch:
Today’s customer expects 24–48h delivery. Not everyone will accept a 4–7 day wait for a parcel travelling from Poland to Western Europe. The higher the product value, the more important speed and predictability become.

Example:
A Polish store selling natural cosmetics to Germany and Austria from a warehouse near Wrocław. Great margins — but a 5-day delivery time. The result? Conversion is lower than that of competitors using a local hub in Hamburg.

Local fulfilment warehouse — closer to the customer, higher for you

The second model is a local warehouse in the target country — for example, in Germany, the Netherlands or Italy. Cost per square metre is higher than in Poland, but you gain:

  • Faster delivery (24–48h)

  • Lower last-mile costs

  • Easier returns (local address)

This model is most popular with premium brands offering high-basket-value products or categories where speed is crucial (e.g. beauty, fashion, electronics).

Example:
A fashion brand moved part of its stock to a warehouse in Berlin. Conversion in Germany jumped by 35%, the return rate stayed the same — but handling costs dropped, as they no longer needed to ship returns back to Poland.

Hybrid model — the best of both worlds

More and more mid-sized brands are testing a hybrid model. What does that mean? The bulk of stock stays in Poland (where it’s cheaper and easier to manage) but top-selling SKUs are permanently stored in a local warehouse in the destination country. This shortens delivery times where it really matters, lets you test demand on new markets, and saves you from burning budget on storing your entire inventory abroad.

Example:
A supplement store decided to keep 80% of its inventory at a fulfilment centre in Poland and 20% (top 50 SKUs) in Prague and Munich. The result? Faster shipping for Czech and German customers, while the rest is sent from Poland. Costs and speed optimised.

Key takeaway

Cross-border starts with your online store — but success is built on choosing the right logistics model for your customers. Remember: the best model is not the cheapest today, but the one that pays off tomorrow. Don’t assume that a customer who waits 7 days once will come back. Next time they’ll choose someone who delivers the same in 48 hours.


Logistics model Delivery cost Delivery time Return cost Scalability
Central (PL) Low ✅ Medium ⚠️ High ❌ High ✅
Local (EU) Medium ⚠️ Short ✅ Low ✅ Medium ⚠️
Hybrid Optimal ✅ Short ✅ Optimal ✅ High ✅

Fulfilio has been delivering tailored logistics, warehousing and fulfilment solutions for 20 years. If you need expert cross-border advice, you can count on proven solutions, a flexible cost plan to match your budget, professional support and the ability to scale as you grow.

Poland as a logistics hub — cost magnet or real advantage?

You’ve probably heard it before: “Poland is the logistics hub of Central and Eastern Europe.” Sounds good — but what does that really mean in practice? And does it genuinely give your cross-border store an edge?

Hard numbers: cost, location, capacity

Let’s break down the facts that matter when choosing a logistics partner.

First, cost. Renting class A warehouse space in Poland in 2025 averages €4–5 per m²/month. In Germany or the Netherlands, it starts at €8–10/m² — and in London, it can hit €15–20/m².

Add labour time. According to Eurostat, the average hourly wage in logistics in Poland is still 30–50% lower than in Germany or Belgium — despite rising pay levels. So running a large central warehouse in Poland remains significantly cheaper than in Western Europe.

But price alone is not enough. A hub must deliver capacity. And Poland does:

  • Over 30 million m² of modern warehouse space (second largest in CEE)

  • Fast-growing road and rail links — express rail to Germany, Czechia, and Baltic ports

  • An expanding network of fulfilment centres serving not only Polish e-commerce but also German, Scandinavian and Balkan online stores

Economies of scale and a new specialisation

Big players like Amazon, Zalando, Allegro invest in Polish logistics centres not because it’s trendy — but because they can supply Germany, Austria or Benelux from one point within 48 hours. A Polish warehouse can reach Berlin overnight by truck, matching local German transit times but with 20–30% lower fixed costs.

More companies now combine this with local consolidation points. For example, operators like InPost and Allegro are expanding parcel lockers and PUDO points in Germany and Czechia — shortening the last mile and cutting return costs.

Real-life example:

One mid-sized cosmetics brand moved all its stock to Germany in 2022. The cost per square metre + return handling ate up around €12,000/month. In 2024, they moved the main stock back to Poland, keeping only a small local buffer in Germany. The result?

  • Storage costs dropped by 45%

  • Delivery time increased by just one day (thanks to smart carrier integration)

  • Total return costs fell by 30% thanks to a local returns partner who sorts parcels in Germany and sends them back to Poland weekly.

Where are the limits?

Not everything can be solved from Poland. For ultra-premium products needing same-day delivery, a local warehouse in Hamburg or Paris is still essential. But for most categories — fashion, cosmetics, hobby, supplements, consumer electronics — a hybrid model with a central hub in Poland and local support works best.

Bottom line:
Poland isn’t just a “cheap fallback” — it’s a real hub that gives you cost, operational and scaling advantages in the region. For e-commerce, this is not a marketing slogan — it’s real money that stays in your margin.

Cross-border in practice: your checklist before you ship

Even the best product and lowest price won’t help if your logistics crumble with the first wave of orders. Cross-border is a marathon, not a sprint — and the list of things to set up beforehand surprises anyone who thinks you just need to translate your store and ship.


Area What to check? Why it matters
VAT €10,000 annual threshold Over the threshold = OSS/IOSS registration required
  VAT rates in destination countries Differences: Germany 19%, Ireland 23% — errors = fines
  Correct invoices & reporting Audits = marketplace account block
Storage What to hold locally vs. in PL Hybrid model = best cost vs. delivery time
  Local fulfilment partner Enables fast shipping & returns
  Calculate storage cost vs. revenue Local stock is pricier, but boosts conversion
Returns & service Local return laws E.g. Germany: free returns within 14 days
  Local return address Cheaper than sending individual parcels back
  Clear return policy Builds trust & reduces complaints
Customs Customs clearance (non-EU) Avoids blocked parcels & hidden fees
  Final cost shown in basket Transparency = fewer abandoned carts
  Customs broker partner Frees up your team & prevents errors
Delivery & testing Order your own product Check real delivery time & cost
  Tracking & comms Customer sees parcel status = fewer queries
  Return process in practice Test how real returns work — it’s crucial

Cross-border: easy conclusion, harder execution

Cross-border selling was once an optional add-on. Today, for many stores it’s Plan B, C and D in one. Remember: when the local market slows down or competition slashes margins to zero, foreign sales create new room to grow — if you know how to run your logistics properly.

Shoppers buy where it’s faster, cheaper and more predictable. If you plan and execute pricing, logistics and returns well, you win loyalty and repeat sales. Ignore VAT, returns or warehouse planning, and at best you’ll lose margin — at worst, your cross-border operation will collapse before it takes off.

What now?

You don’t need to memorise every regulation. You don’t need five warehouses overnight. But you do need a plan — and partners who’ll back you up.

Want to check if your store is ready for cross-border?
Book a free call with our expert. We’ll review your logistics, costs and give you concrete recommendations on how to grow internationally without risk or wasted budget.

 

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Logistics for e-Commerce

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Rafał Kuczmarski

Head of Sales 

Fulfilio is the administrator of your data. Your data is processed to respond to your inquiry. The GDPR gives you the right to access your data and object to the processing. More information about your rights and data processing can be found in the Privacy Policy.

Foto-150x150-1.png

Rafał Kuczmarski

Head of Sales 

Fulfilio is the administrator of your data. Your data is processed to respond to your inquiry. The GDPR gives you the right to access your data and object to the processing. More information about your rights and data processing can be found in the Privacy Policy.

Foto-150x150-1.png

Rafał Kuczmarski

Head of Sales 

Fulfilio is the administrator of your data. Your data is processed to respond to your inquiry. The GDPR gives you the right to access your data and object to the processing. More information about your rights and data processing can be found in the Privacy Policy.

Foto-150x150-1.png

Rafał Kuczmarski

Head of Sales 

Fulfilio is the administrator of your data. Your data is processed to respond to your inquiry. The GDPR gives you the right to access your data and object to the processing. More information about your rights and data processing can be found in the Privacy Policy.

Foto-150x150-1.png

Rafał Kuczmarski

Head of Sales 

Fulfilio is the administrator of your data. Your data is processed to respond to your inquiry. The GDPR gives you the right to access your data and object to the processing. More information about your rights and data processing can be found in the Privacy Policy.