How to package lithium-ion batteries for shipping
Lithium-ion batteries are now everywhere, from consumer electronics and power tools to electric vehicles and large-scale energy storage. But transporting them safely requires more thought than simply choosing a strong box.
Classified as dangerous goods, they are subject to a range of regulations governing how they are tested, packaged, marked and transported. The exact requirements can vary depending on the battery, its condition and whether it is travelling by road, sea or air.
At Tri-Wall, we design, manufacture and test dangerous-goods packaging and have been closely involved in research into safer lithium-ion battery transportation. So, what do manufacturers and distributors need to consider before a battery begins its journey?
Why do lithium-ion batteries need specialist packaging?
Lithium-ion batteries store a large amount of energy in a relatively small space. If a cell is damaged, overheated, short-circuited or otherwise compromised, it can enter a process known as thermal runaway, where rapidly increasing temperatures can lead to fire and potentially affect neighbouring cells.
This was one of the areas explored through LIBRIS – Lithium-Ion Battery Research in Safety – a government-funded research and development programme involving Tri-Wall alongside organisations including Jaguar Land Rover, the Health and Safety Executive and Warwick Manufacturing Group. Live-cell testing carried out as part of the programme examined how heat, gases and other effects can behave during thermal runaway.
Packaging therefore has an important job to do. As well as protecting the battery from impact and movement during normal handling and transportation, it may need to help prevent short circuits and meet specific dangerous-goods requirements.
What are the lithium-ion battery packaging requirements?
There is no single set of lithium-ion battery packaging requirements that applies to every shipment.
Before choosing a pack, you need to establish exactly what you are transporting. Relevant factors can include:
- whether you are shipping individual cells or complete batteries
- whether batteries are being shipped alone, packed with equipment or contained within equipment
- battery size and weight
- the watt-hour (Wh) rating of the battery
- whether the battery has passed the applicable UN 38.3 tests
- whether it is new, used, damaged, defective or being sent for disposal or recycling
- whether it will travel by road, sea or air
The applicable packing instructions then depend on that classification.
For example, UNECE packing instruction P903 covers a number of lithium-ion battery scenarios and includes requirements designed to protect cells and batteries against damage and movement within the packaging. Larger batteries with robust casings may be subject to different provisions.
Air transport introduces additional requirements. IATA guidance specifies different packing instructions depending on whether lithium-ion batteries are shipped on their own, packed with equipment or contained in equipment. Current rules also include state-of-charge restrictions for some air shipments.
Determining the battery condition is essential before selecting the correct packaging solution.
How to package lithium-ion batteries for shipping
The exact process will depend on the shipment, but there are some useful principles to follow.
1. Identify the battery and its condition
Start by confirming what you are shipping, including its type, weight, Watt-hour rating, configuration and UN 38.3 status.
Its condition matters too. A battery that is damaged, defective or being returned for recycling can require very different packaging from a new battery in good condition.
2. Select packaging for the relevant classification
Once the battery has been classified, select packaging that meets the applicable transport and dangerous-goods requirements.
Depending on the application, this could include UN-certified fibreboard, timber or combination packaging, or a solution designed around a larger battery pack.
3. Protect against movement and short circuits
Batteries should be secured so they cannot move around inside the packaging during handling and transportation.
Terminals may also need protection from contact with conductive materials or other batteries. UNECE guidance for lithium batteries specifically addresses protection from damage and inadvertent movement during transport.
Internal trays, dividers, cushioning and bespoke fittings can all help hold the battery securely in place.
4. Consider the specific risks of the battery
Packaging requirements should reflect more than dimensions and weight.
Large automotive batteries, for example, can present very different handling and containment challenges from small cells. Where the risk assessment calls for it, specialist materials or design features may also be used to help manage the effects of thermal runaway.
Tri-Wall’s LIBRIS work included development and testing of packaging incorporating thermal-mitigation materials for cells, modules and larger battery packs.
5. Check marking, labelling and documentation
Correct packaging is only one part of compliance.
Lithium-ion shipments can also require specific marks, labels and documentation according to their classification and method of transport. The UK Competent Authority makes clear that businesses transporting dangerous goods must follow the relevant requirements for both packing and labelling.
Because requirements can change, always check the current rules that apply to the shipment before dispatch.
What lithium-ion battery packaging materials can be used?
The right lithium-ion battery packaging materials depend on the battery, its condition and its journey.
Corrugated fibreboard can provide a lightweight, efficient solution for many cells and smaller battery formats. Heavy-duty corrugated designs can also be engineered for larger or more demanding applications.
Timber and plywood can provide additional structural strength for heavy modules and complete vehicle battery packs, while plastic and combination packaging may be appropriate in other applications.
Internal packaging is just as important as the outer pack. Foams, trays and dividers can be used to secure batteries, maintain separation and reduce movement, while specialist thermal-mitigation materials may be incorporated where the application requires them.
Tri-Wall’s lithium-ion packaging development work has included scalable corrugated and timber solutions for cylindrical, pouch and prismatic cells, modules and full vehicle battery packs.
The important point is that the packaging material should be selected around the actual risk and transport requirements rather than simply using a standard solution for every battery.
What if a lithium-ion battery is damaged or defective?
Damaged or defective batteries require particular care.
A battery that has been dropped, crushed, overheated, swollen or otherwise compromised may present a higher risk than one in normal condition. Batteries being sent for disposal or recycling can also fall under different packing requirements.
Do not assume packaging used for new batteries can simply be reused for these shipments.
Tri-Wall’s research and development work has included packaging specifically aimed at defective and end-of-life batteries, including solutions designed around heat resistance, containment and controlled gas release.
If you are unsure how a battery should be classified or packaged, seek specialist dangerous-goods advice before arranging transport.
Does lithium-ion battery packaging need to be tested?
In many cases, dangerous-goods packaging must meet specific performance and require certification.
It is important to distinguish this from UN 38.3 testing. UN 38.3 relates to the cell or battery itself and assesses its suitability for transport under a series of specified conditions. Packaging testing assesses whether the packaging design meets the requirements relevant to the dangerous goods it will carry.
Tri-Wall designs, manufactures and tests dangerous-goods packaging in accordance with the United Nations Model Regulations and applicable ADR, ICAO, IATA and IMDG requirements. Its accredited dangerous-goods testing covers fibreboard, timber, metal and plastic combination boxes.
Tri-Wall can also independently test packaging manufactured by other suppliers, with its dangerous-goods testing facility able to accommodate packaging with a gross mass of up to 2,500kg.
Where requirements fall outside its accreditation schedule, external testing can be sourced through its specialist network.
What should you look for in a lithium-ion battery packaging supplier?
Packaging lithium-ion batteries safely means considering the battery, the packaging and the entire transport journey together.
Look for a supplier that understands dangerous-goods regulations, can design around the specific battery or module, works across different packaging materials and has access to appropriate testing.
Experience with damaged and end-of-life batteries can also be important, particularly as battery reuse, recycling and second-life applications continue to grow.
The Tri-Wall difference: lithium-ion expertise built on research
Tri-Wall’s approach to lithium-ion battery packaging is informed by years of research, development and practical testing.
Through the LIBRIS programme, we worked alongside automotive, academic, government and materials specialists to investigate the risks associated with transporting lithium-ion batteries and develop packaging solutions informed by live-cell testing.
Today, we combine that knowledge with dangerous-goods packaging design, manufacture and accredited testing to help customers find solutions suited to their batteries, supply chains and transportation requirements. Lithium-ion batteries and their packaging are subject to a range of regulations, including UN Dangerous Goods Regulations and requirements established by international transport authorities. We not only meet these standards but also strive to set new benchmarks in quality, safety and compliance.
Need help packaging lithium-ion batteries for transport?
We’re here to help. Speak to our packaging experts today and we’ll help you identify the right packaging approach for your product and journey.
