Lithium-Ion packaging

How do you prepare UN3480 shipping labels for lithium-ion transport?

Summary

8 minutes reading time

Michel Prins

Accountmanager Safety & Security

Michel Prins is Account Manager at Faes and a specialist in Safety & Security. Thanks to his background at the Ministry of Defense and years of experience in the sector, he advises organizations on reliable packaging solutions for critical applications. He combines practical knowledge with technical expertise to package sensitive equipment safely and efficiently.

What are UN3480 shipping labels and why are they mandatory?

UN3480 shipping labels are standardised warning labels specifically designed for the transport of lithium-ion batteries. These labels are internationally mandatory under dangerous goods regulations because lithium-ion batteries pose a fire hazard and, under certain circumstances, can even spontaneously combust. The UN3480 classification is specifically assigned to lithium-ion batteries that are shipped as separate items (not installed in equipment). This classification falls under international regulations for dangerous goods, including:

IATA Dangerous Goods Regulations (air transport)
IMO IMDG Code (maritime transport)
ADR (European road transport)
DOT Hazardous Materials Regulations (US transport)

The requirement for these labels is not merely a bureaucratic formality. They play an essential role in ensuring safety during transport. When carriers and emergency services can immediately identify that a package contains lithium-ion batteries, they can take the appropriate precautions and respond effectively in the event of an incident. Furthermore, these labels assist in the correct stacking and storage of the packages, taking into account factors such as temperature and proximity to other hazardous substances that may react with lithium-ion batteries.

What information must appear on a UN3480 shipping label?

A correct UN3480 shipping label contains several mandatory elements, each serving a specific purpose. Ensure your label includes the following information:

UN number: UN3480 must be clearly visible
Correct shipping name: “Lithium-ion batteries” (in English, even when shipping from the Netherlands)
Hazard class: Class 9 – Miscellaneous dangerous substances and articles
Hazard symbol: The Class 9 symbol (seven vertical black stripes in the upper half and a battery symbol, flame and the number 9 in the lower half)
Telephone number: A 24/7 emergency number for information in the event of incidents

In addition, the label must include a handling mark – a special marking indicating that the contents are lithium batteries. This is a rectangular label with a red border, containing the UN number, a telephone number and symbols indicating that damaged packages may pose a fire hazard. For international shipments, you must also take into account:

Language requirements (some countries require labels in the local language)
Label dimensions (minimum 120 x 110 mm for most transport methods)
Durability (resistant to outdoor conditions without noticeable deterioration in quality)

In addition to the label itself, you must also include a transport document (e.g. a consignment note) containing detailed information about the shipment, including the number of packages, the total weight and a declaration that the batteries comply with the relevant test criteria.

How does labelling for loose cells differ from that for complete battery packs?

The labelling requirements for lithium-ion batteries vary depending on the configuration in which they are shipped. There are significant differences between loose cells and complete battery packs: Loose lithium-ion cells (individual battery cells):

Fall under UN3480, but may sometimes require specific additional markings indicating that they are individual cells
Require information on the watt-hour rating (Wh) of each cell
Often have less stringent packaging requirements than complete battery packs
Must generally be individually protected against short circuits

Complete lithium-ion battery packs (multiple cells combined into a single unit):

Also fall under UN3480, but with additional requirements
Require information on both the total watt-hour rating and the number of cells in the pack
Have stricter packaging requirements due to the higher energy content
Must be fitted with protection against accidental activation

In addition, there are special rules for prototypes, small production runs (fewer than 100 units) and for batteries being shipped for disposal or recycling. These often require additional documentation and specific packaging requirements. It is important to note that batteries with a capacity exceeding 100Wh are subject to stricter regulations than those with a lower capacity. For high-capacity batteries, additional restrictions apply regarding transport methods and maximum quantities per shipment.

What are the consequences of incorrect UN3480 labelling?

Incorrect labelling of lithium-ion batteries for transport can have far-reaching consequences in various areas: Safety risks:

Increased risk of accidents during transport because handlers are unaware they are handling dangerous goods
Incorrect handling or storage, which can cause batteries to become damaged or overheat
Delayed or inadequate response to incidents due to a lack of correct information

Legal consequences:

Substantial fines from transport authorities (these can run into tens of thousands of euros)
Criminal prosecution in the event of serious violations or incidents
Liability for damage or injury caused by incorrect labelling

Business impact:

Shipments may be refused, delayed or returned
Higher transport costs due to reshipments or express deliveries
Damage to reputation among customers and partners
Potential loss of licences for shipping dangerous goods

A real-life example: in 2021, the US Federal Aviation Administration (FAA) imposed a fine of $91,000 on a company that had shipped lithium-ion batteries without proper labelling and documentation. This underscores how seriously regulators take these violations. Given these risks, it is crucial to always follow the latest regulations and to properly train your team on the correct procedures for shipping lithium-ion batteries.

Where can you obtain certified UN3480 shipping labels?

There are several reliable sources available for obtaining certified UN3480 shipping labels: Specialist suppliers:

Packaging specialists offering certified hazardous materials labels
Industrial label manufacturers with expertise in ADR regulations
Online suppliers specifically selling UN3480 labels in accordance with international standards

Transport companies and freight forwarders:

Many large transport companies offer certified labels to their customers
Freight forwarders can often assist with the correct labelling of shipments
Some courier services have special services for dangerous goods, including label provision

Printing and design solutions:

Specialised software for creating compliant shipping labels
Printing services capable of producing certified labels in accordance with the latest regulations
In-house printing solutions with pre-approved templates

When choosing a supplier for your UN3480 labels, consider these key factors:

Certification: Ensure the labels comply with the latest international regulations
Material specifications: Labels must be durable and withstand various conditions
Up-to-date: Regulations for dangerous goods are regularly updated, so ensure your labels are up to date

For companies that regularly ship lithium-ion batteries, it is often most efficient to work with a specialist packaging partner who can not only supply labels but also advise on the complete packaging solution. At Faes, we have extensive experience in packaging and shipping sensitive and hazardous materials, including lithium-ion batteries for defence and security applications.

Conclusion

Preparing UN3480 shipping labels correctly for lithium-ion batteries is not an optional formality, but an essential safety measure and a legal obligation. By using the correct labels, you not only protect your shipment but also the people who come into contact with it during transport. Ensure that your labels contain all the required information, that they are clearly visible on your packaging, and that they comply with the latest international regulations. Also take into account the specific requirements for different configurations of lithium-ion batteries. With the right knowledge and preparation, you can ensure that your lithium-ion batteries reach their destination safely and in compliance with all regulations, without delays or fines. Investing in correct labelling and packaging is ultimately far more cost-effective than the potential costs of non-compliance. At Faes, we understand the complexity of shipping sensitive and potentially hazardous goods. We are happy to assist you with bespoke packaging solutions that comply with all relevant regulations, so that you can focus on your core business.

Frequently Asked Questions

How often are the regulations for UN3480 shipping labels updated?

International regulations for the shipment of dangerous goods, including lithium-ion batteries, are typically updated every two years. The IATA Dangerous Goods Regulations are reviewed annually, whilst ADR, IMDG and other codes usually follow a biennial update cycle. It is essential to set up a system for monitoring these changes, for example via newsletters from regulatory bodies or by working with a specialist logistics partner who keeps you informed of relevant changes.

What should I do if a lithium-ion battery is damaged during transport?

If a lithium-ion battery is damaged during transport, you must act immediately: 1) Isolate the package from other shipments and keep it away from flammable materials, 2) Contact professionals trained in handling hazardous materials, 3) Document the incident carefully with photographs and written reports, 4) Report the incident to the relevant authorities, such as the Inspectorate for the Environment and Transport. Prevent further handling of the damaged battery without protective equipment and always follow the specific emergency procedures outlined in your safety documentation.

Can I pack different types of lithium batteries together under a single UN3480 label?

No, different types of lithium batteries must not be packed together under a single UN3480 label. UN3480 applies specifically to loose lithium-ion batteries. Lithium-metal batteries fall under UN3090, whilst batteries contained in equipment fall under UN3481 (lithium-ion) or UN3091 (lithium-metal) respectively. Mixing different battery types in a single package is not permitted under international regulations. Each type of battery requires its own specific packaging, labelling and documentation to guarantee safe transport and ensure compliance with regulations.