Strict international standards apply to the safe transport of lithium-ion batteries due to the high risk of fire and explosion. This article explains which regulations apply, which UN-certified packaging is required, and how companies can limit risks with the right materials and procedures.
Summary of this article
Lithium-ion batteries are being used more and more frequently in products, machinery and equipment. As a result, their transport is also on the rise. However, the transport of these batteries requires extra care: damage, overheating or short-circuiting can lead to fire, leakage or other hazardous situations. Furthermore, there are strict international regulations governing packaging, documentation and certification. In this article, you will learn why safe transport is so important, what risks and obligations are involved, and how suitable, certified packaging helps to ensure that lithium-ion batteries are transported responsibly.
Lithium batteries are the energy source of modern industry. They are used in high-tech production machinery, medical equipment, drones, communication systems and countless other applications. Their high energy density and chemical composition make them efficient and powerful, but also susceptible to damage and overheating. This poses significant risks during transport and storage.
In recent years, there has been a sharp increase in the number of incidents involving lithium batteries. Fires, smoke development and explosions occur regularly when batteries are incorrectly packaged or transported in a damaged condition. Strict international rules apply to limit these risks. Lithium batteries are classified as dangerous goods by the United Nations and therefore have a UN number (such as 3480, 3481, 3090 and 3091). This classification means that they must meet additional requirements for packaging, handling and documentation during transport.
The specific regulations for this are laid down in international legislation and regulations: for road transport in the ADR, for air transport in the ICAO-TI / IATA-DGR, for sea transport in the IMDG code, for rail transport in the RID and for inland waterway transport in the ADN. To demonstrate that packaging meets these requirements, it must be tested and approved in accordance with the applicable standards. After successful testing, the packaging is given a UN mark, which demonstrates that it is suitable for the safe transport of lithium batteries.
For companies in sectors such as high-tech, medical technology and defence, this means that packaging is not just a logistical task, but an essential part of risk management and compliance. Incorrect packaging can lead to damage to products, downtime in the chain or legal consequences in the event of incidents. The relevance of this topic therefore lies in safety, business continuity and compliance with laws and regulations.
At Faes, we are seeing rapid growth in demand for certified packaging solutions for lithium batteries. Customers want certainty that their products not only meet the requirements, but are also demonstrably safe in practice. That is why we combine knowledge of regulations with packaging engineering, testing and logistics expertise. In this way, we help companies manage their risks and operate safely within the applicable standards.
Lithium batteries contain a lot of energy in a compact form. If this energy is released in an uncontrolled manner, it can lead to serious safety risks. The greatest dangers arise from damage, overheating or internal short circuits, which can cause a so-called thermal runaway. In such a situation, the battery heats itself up to the point where combustion or explosion is possible. This can release toxic gases that are not only dangerous to humans, but also increase the risk of fire and explosion.
Incorrect packaging or handling during transport significantly increases these risks. If batteries are insufficiently protected against shocks, vibrations or temperature fluctuations, this can lead to structural damage to the cells. Even a small deformation or crack can be enough to cause thermal runaway.
Incorrect labelling or documentation can also lead to delays or refusal of transport, resulting in financial damage and loss of reputation. Because the transport of lithium batteries is subject to ADR legislation, such errors can also have legal consequences. The Human Environment and Transport Inspectorate (IL&T) strictly enforces these regulations and can immediately impose fines or halt transport in the event of violations.
Incidents involving lithium batteries in recent years have shown that the consequences can be far-reaching. Fires in distribution centres or loading areas not only cause material damage, but also lead to prolonged downtime and high repair costs. In addition, companies can be held liable if it appears that they did not comply with the applicable regulations for the transport of dangerous goods, as laid down in the ADR, the IATA-DGR or the IMDG Code.
Safe and certified packaging is therefore not a formality, but a necessary measure to control risks. By successfully passing the prescribed tests, the packaging obtains a UN mark or certificate, which companies use to demonstrate that they are taking responsibility for the safe transport and storage of lithium batteries. It is equally important to strictly follow the accompanying packaging instructions: if batteries are not placed correctly in the approved packaging, transport remains unsafe. This prevents accidents, protects staff and the environment, and strengthens the confidence of customers and partners.
Anyone who wants to package or transport lithium batteries has to deal with a complex set of international regulations. These rules have been drawn up to ensure safety during transport and to prevent incidents. The legal basis for road transport is laid down in the ADR. Air transport is governed by the ICAO-TI / IATA-DGR, sea transport by the IMDG Code, rail transport by the RID and inland waterway transport by the ADN.
Within these regulations, lithium batteries have been classified as dangerous goods by the United Nations, with corresponding UN numbers indicating the type:
Specific requirements apply to each type in terms of packaging, labelling, marking and documentation. In addition, these regulations distinguish between the status of the batteries, as this affects the packaging requirements:
Due to this complexity, it is essential to determine for each battery type which requirements apply and which packaging demonstrably meets the appropriate test standards and certification.
Packaging for lithium batteries must not only comply with the correct UN classification, but also be demonstrably safe for use during transport. To qualify, the packaging must be tested in accordance with the test methods set out in the UN Manual of Tests and Criteria. These tests, including drop, shock and stacking tests, demonstrate that the packaging can withstand the physical forces that may occur during transport.
In addition to this packaging inspection, the batteries themselves are subject to the UN 38.3 test. This is an internationally mandatory series of safety tests that checks whether lithium batteries are safe under typical transport conditions, such as pressure, temperature and vibration differences. Only batteries that successfully pass all test phases may be transported worldwide. The corresponding UN 38.3 certificate is therefore an essential requirement for manufacturers, importers and distributors to ship lithium batteries legally and safely.
In addition to physical testing, administrative requirements play an important role. Each shipment must be correctly labelled and provided with the correct hazard label in accordance with ADR class 9A, which applies to lithium batteries (with the exception of batteries covered by Special Provision 188). The transport document and CMR consignment note must also be completed fully and correctly. Incomplete or incorrect documentation can lead to delays, refusal of the shipment or fines.
When designing packaging, it is important to take into account the conditions in which it will be used. Consider temperature fluctuations, air transport or storage in humid environments. The type of battery and its capacity also determine the requirements. Well-designed packaging not only takes regulations into account, but also practical factors such as handling, reusability and cost control.
By paying attention to these aspects at an early stage, companies can limit risks and comply with all applicable requirements. This forms the basis for a safe, efficient and compliant packaging process.
At Faes, we guide you through the entire process of packaging lithium-ion batteries. This ensures you have a safe, certified solution that not only complies with international transport regulations, such as ADR, IATA DGR, IMDG, RID and ADN, but also performs optimally in practice. Our approach consists of four key steps that together ensure safety, efficiency and regulatory compliance.
Together with the customer, we identify all relevant product and transport characteristics. We analyse the type of battery, its capacity, the configuration of cells and the conditions during transport. We also take into account the customer’s wishes in terms of packaging and transport. We then determine which UN certification applies, such as UN 3480 or UN 3481, and which additional requirements apply for air, sea or road transport. This analysis forms the basis for the design of the packaging and the test requirements in accordance with the applicable standards.
Our engineers translate the technical specifications into packaging that meets all safety and certification requirements. This involves considering the choice of materials, construction and internal protection that insulates and stabilises the batteries. Where necessary, we integrate fire-retardant or shock-absorbing materials to minimise the risks of overheating and damage. Findings from previous tests and practical experience are directly incorporated into the design.
Faes works with recognised testing bodies to have the packaging validated according to the appropriate international standards. We take care of the logistical coordination, deliver the packaging to the testing laboratory and ensure that all required documentation, such as test reports and certification files, is complete and correctly available. This provides objective proof that the packaging meets the requirements for the safe packaging of lithium-ion batteries.
After the testing process, we carefully analyse the results and discuss them with the customer. Where optimisation is possible, we adjust the design or choice of materials so that the packaging not only complies with the standard, but can also be used reliably in practice over the long term.
Thanks to this structured approach, we deliver packaging solutions that comply with international safety standards and are perfectly suited to our customers’ operational realities. Faes thus combines technical certainty with practical applicability for the safe and compliant transport of lithium-ion batteries.
Do you want to be sure that your lithium batteries are transported safely, certified and in accordance with the relevant regulations?
Then contact Faes for a no-obligation consultation. Our specialists will be happy to help you with a tailor-made solution, from design to certification and logistical implementation.
Tim van de Puttelaar is the Engineering Manager at Faes and specializes in packaging engineering and custom solutions. In his articles, he shares insights on optimization, testing, and engineering projects that contribute to more efficient and sustainable packaging solutions within complex supply chains.
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