How To Ship Batteries Safely: A Complete Packaging Guide

Sanidhya Negi / December 7, 2024

Batteries power devices and tools that keep our world moving, such as laptops, electric vehicles, and even medical equipment. As their demand rises, so does the need to transport them safely.

Shipping batteries, especially lithium ones, requires careful handling due to the risks of fire, explosion, or other hazards if not packed correctly. Learning how to ship batteries properly ensures safety, compliance, and peace of mind for all involved. Whether you’re shipping a single unit or bulk quantities, understanding the process to ship lithium batteries is crucial to avoid potential accidents or penalties. 

This guide will cover everything you need to know to make battery transportation secure and hassle-free.

Types of Batteries and their Shipping Guidelines

Shipping batteries require careful attention to their type and specific handling requirements. Below is a guide to shipping wet and dry batteries safely and in compliance with regulations.

Wet Batteries

Wet Batteries, also called lead-acid batteries, are widely used, in utility systems, and industrial machinery. These batteries contain corrosive substances such as acid or alkali, classifying them as regulated shipments under Class 8 (Corrosive).

Packaging Guidelines for Wet Batteries

Leakproof Containers: Use containers lined with acid/ alkali-proof barriers to prevent leaks.

Battery Positioning: Batteries should be fastened securely with vents and fill openings facing upward to avoid overheating or short-circuit.

Use of Dividers: When Shipping multiple batteries, separate them using non-conductive dividers to prevent contact.

Sealing and Labeling: Seal the packaging with durable tape to prevent leaks. Also, ensure accurate labeling on the battery to meet the necessary compliances. 

Dry Batteries

Dry batteries are sealed, non-vented batteries commonly found in flashlights, small appliances, and other portable devices. 

Packaging Guidelines for Dry Batteries

Sturdy Outer Containers: Place batteries in robust packaging to ensure stability during transit.

Battery Placement: You must secure multiple batteries side by side with dividers.

Void Filling: Fill void spaces within the packaging to prevent movement.

Sealing and Labeling: Use the H-taping method with wide, pressure-sensitive adhesive tape to seal the package. Then properly label the package with all required markings to comply with shipping standards for batteries, including lithium battery shipping requirements.

Common Packing Guidelines For Different Types of Batteries

Proper packaging is essential when figuring out how to ship batteries safely and efficiently. Each type of battery requires special care to ensure compliance with safety regulations and to minimize risks during transit. Here are some essential packaging practices:

Use Protective Inner Packaging: Batteries must be placed in inner packaging that completely surrounds them, such as fiberboard boxes. This layer acts as a shield to prevent potential short circuits and ensures the battery remains intact and safe during handling and transport.

Strong Outer Packaging: The inner packaging should then be placed within a sturdy outer container made of materials like fiberboard, wood, or metal. This strong, rigid outer packaging offers protection against impacts, pressure, or crushing, which is especially important during long-distance shipping.

Cushioning for Batteries: When shipping batteries, both inner and outer packaging must be accompanied by sufficient cushioning material. The cushioning minimizes movement, absorbs shocks, and provides extra protection to avoid damage to these sensitive power sources.

Ensure Leakproof Packaging: All packaging must be sealed securely to prevent leaks, particularly in the case of batteries that contain electrolytes. The packaging should be capable of containing any spills, as even minor punctures or tears can make it unsuitable for shipping.

Keep Batteries Upright and Separated: To reduce the risk of short circuits, batteries should always be positioned upright within the packaging. Proper securing methods, such as separators or dividers, can help keep them steady. It’s also critical to avoid placing battery shipments near heat sources or other items that may create unnecessary risks.

Guidelines For Shipping Lithium Batteries

Shipping lithium batteries requires strict adherence to specific regulations to ensure safety during transit. Below is a simplified overview of the guidelines for lithium battery shipping.

Individual Packaging: Each lithium battery should be enclosed in protective packaging, such as plastic blister packs or sturdy boxes, to prevent damage.

Prevent Short Circuits: Shield batteries to avoid contact with conductive materials that could cause a short circuit.

Tested Packaging: Use packaging that meets safety standards outlined in the UN Manual of Tests and Criteria (Part III, Section 38.3).

Secure Positioning: Ensure batteries are either fully enclosed, e.g., in equipment or protective wrapping) or secured in place to prevent movement during shipping.

Outer Containers: Place all inner packaging inside a strong, durable outer box.

Proper Labeling: Label packages with the correct information and include all required documentation.

Essential Documentation for Battery Shipping

Shipping batteries internationally requires specific documents to ensure compliance and safety. The necessary documents required for shipping batteries are mentioned below.

Declaration of Dangerous Goods (DGD): This document provides detailed information about the shipment, including, UN number, shipping name, hazard classification, packaging group, and quantity of batteries being shipped.

Emergency Handling Guidelines: Carriers must have instructions to manage emergencies such as leaks, fires, or damage during transit. This information is crucial for all battery shipments.

Material Safety Data Sheet (MSDS): An MSDS contains detailed product information, potential hazards, and safety instructions. It is required for all types of batteries being shipped.

Pilot Notification for Air Shipments: When shipping lithium batteries by air, pilots must receive a written notice detailing the presence, quantity, and location of the batteries onboard.

Packaging Compliance Certificates: This document confirms that the packaging used meets the regulatory safety and performance standards.

Battery Test Reports: For damaged or defective lithium batteries, a test summary proving compliance with transportation standards is required.

Exemption Approval Documents: If an exemption from dangerous goods regulations is granted, these documents must accompany the shipment.

Conclusion

Shipping batteries, especially lithium batteries, requires strict adherence to international regulations and proper documentation to ensure safety and compliance. From packaging certifications to emergency response details, every step plays a crucial role in smooth and secure transportation. Whether shipping lithium batteries by sea or air, following the right protocols is essential.

For seamless and reliable shipping, you can partner with Bigship, a trusted logistics service operating in 220+ countries. Bigship, through its expertise in battery transportation, simplifies the process of how to ship batteries and ensures efficiency and compliance at every step.

Sign Up with Bigship and start shipping batteries globally!

FAQs

Ques: Why is shipping lithium batteries so heavily restricted?

Ans: Lithium batteries pose a fire risk if damaged during transport, thus, making strict shipping regulations essential for safety.

Ques: Is shipping lithium-ion batteries more expensive?

Ans: Some couriers may charge extra fees for transporting hazardous items like lithium-ion batteries due to safety regulations. You must always check with the courier company regarding additional charges.

Ques: Can I ship lithium batteries at full charge?

Ans: No, lithium-ion batteries must be shipped at no more than 30% of their full charge capacity.