Li-ion batteries offer great convenience but also pose serious safety risks during storage and transport. With the right packaging and precautions, you can limit the risk of fire and comply with the necessary safety standards.
Summary of this article
Lithium-ion batteries are now found almost everywhere. They are rechargeable, compact, have a high energy density and offer a relatively long service life. As a result, they have become indispensable in smartphones, tablets, laptops, e-bikes, power tools, machinery and electric vehicles.
However, the use of lithium-ion batteries also has a downside. A battery can become damaged due to a fall, impact, short circuit, high temperature, incorrect charging or an internal defect. In the most serious cases, thermal runaway can occur: a self-reinforcing process in which the temperature inside the battery rises rapidly. This may result in fire, pressure build-up and the release of flammable or toxic gases. These risks can also lead to dangerous situations during transport and storage.
We previously wrote about the safe transport of Li-ion batteries. The applicable transport regulations depend, among other things, on the type of battery, its condition, how it is presented for transport and the selected mode of transport. A distinction may be made between batteries transported separately, batteries packed with equipment and batteries contained in equipment. Damaged or defective batteries require additional precautions and, in some cases, special packaging.
For suitable applications, the plastic, dustproof and waterproof cases from the SKB 3i series can be combined with a custom-made interior. This interior secures the batteries in place and protects them against shocks, vibrations and unwanted contact with other components.
Where required by regulations, the complete combination of case, interior and contents can be tested. Following a successful test, the packaging can be approved in accordance with the applicable regulations and provided with the correct UN marking. This means that it is not only the outer case that matters: the complete packaging configuration must be suitable for the specific battery and the conditions under which it is transported.
PGS 37-2 was developed for the storage of lithium-containing energy carriers. This guideline describes measures that companies can take to manage the risks associated with storing lithium-ion batteries.
PGS 37-2 distinguishes, among other things, between the condition of the energy carriers and the type and scale of the storage facility. New batteries, for example, present different risks from used, refurbished, discarded, damaged or unstable batteries. There is therefore no single set of measures that is automatically suitable for every storage location.
PGS 37-2 has been finalised, but it is not currently directly designated under the Dutch Environmental Activities Decree, known as the Besluit activiteiten leefomgeving. However, the guideline may already play a role in permit conditions, the duty of care, customised regulations and agreements with the competent authority. You should therefore always check which requirements apply to your location and business activities.
There is no single standard measure that eliminates all risks associated with lithium-ion batteries. An effective approach consists of a combination of prevention, early detection, limiting the spread of fire and a well-prepared incident response.
Important points to consider include:
Lithium-ion battery fires can be difficult to control and may continue to generate heat, flammable gases and toxic substances for a prolonged period. The focus should therefore not only be on extinguishing a single battery, but primarily on recognising abnormal conditions at an early stage and preventing escalation to the rest of the storage area.
There is no standard solution for the safe storage of lithium-ion batteries. The required measures depend on factors including the type of battery, the condition of the batteries, the quantity stored and the activities taking place at the location. New batteries, for example, present different risks from used, damaged or defective batteries.
Start by identifying the batteries being stored and the possible incident scenarios. Then consider measures such as a suitable storage location, the separation of high-risk batteries, protection against mechanical damage and short circuits, the timely detection of abnormal conditions and measures to limit the spread of fire.
Damaged, deformed, leaking or unusually warm batteries must be removed from the regular storage area immediately and isolated in accordance with an established procedure. The facilities required for this must be determined based on the risk assessment, PGS 37-2 and the requirements of the competent authority and insurer.
Companies that work with lithium-ion batteries must consider storage and transport together. A battery that is safely stored in a warehouse is not automatically ready for transport. Conversely, transport packaging is not automatically suitable as a permanent storage facility or as a facility for charging batteries.
Faes supports companies in the safe transport and protection of lithium-ion batteries. We assess factors including the battery type, classification, condition, transport mode and practical operating conditions. Our engineers then translate these requirements into suitable packaging, securing and protective solutions. Where necessary, we also coordinate the testing and approval of the packaging type.
When designing and setting up a storage location, we recommend working with a safety specialist, fire safety expert, insurer and the competent authority. This prevents a single product or measure from being incorrectly regarded as a complete solution.
Are you planning to transport lithium-ion batteries, either separately or as part of an electronic product? It is important to first determine which classification, packaging instructions and transport regulations apply. Take into account the condition of the battery, its energy content, the quantities involved and the selected mode of transport.
Submit your question using the contact form below or contact us directly. Please provide as much information as possible about the battery and the transport situation. Based on this information, our packaging experts can assess which packaging solution and any required testing or approval process are needed.
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.
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