From 2025, stricter regulations will apply to the transport of lithium-ion batteries, with more stringent requirements regarding packaging, labelling and charge levels. Faes helps businesses and defence organisations to remain compliant by providing safe and certified packaging solutions.
Summary of this article
The transport of lithium-ion batteries will become increasingly complex by 2025 due to stricter international regulations and growing demand for safe transport solutions. Whether you are shipping military drones, defence equipment or industrial systems, a thorough understanding of safety regulations is essential to ensure compliance and minimise risks. This guide provides a comprehensive overview of all relevant regulations, from UN codes to practical packaging requirements, enabling you to transport your lithium batteries in full compliance.
The classification of lithium-ion batteries for transport is based on specific UN codes that determine which safety measures apply. These codes are crucial for the correct identification and handling of your battery shipments.
UN3480 applies to lithium-ion batteries shipped as standalone goods. This covers loose batteries, battery packs and rechargeable batteries not installed in equipment. The strictest packaging and transport requirements apply to this category, including special documentation and labelling.
UN3481 is used when lithium-ion batteries are shipped together with equipment but are not installed in the device. Think of a drone case containing loose spare batteries alongside the device. This classification has less stringent requirements than UN3480, but still requires specific packaging measures.
For batteries permanently installed in devices, such as in defence drones or industrial systems, UN3091 applies. This code has the least restrictive requirements, but still requires correct documentation and packaging to prevent damage during transport.
| UN-Code | Application | Packaging Group | Special requirements |
| UN3480 | Replaceable lithium-ion batteries | II | Charged to a maximum of 30%, special packaging |
| UN3481 | Batteries with equipment | II | Short-circuit protection |
| UN3091 | Batteries in equipment | II | The device must be switched off |
For road transport within Europe, the ADR regulations (European Agreement concerning the International Carriage of Dangerous Goods by Road) apply. These regulations specify how lithium battery transport by road must be carried out and what documentation is required.
The ADR regulations for 2025 contain important updates regarding maximum quantities per transport unit and required training for drivers. Simplified procedures apply to small quantities of lithium-ion batteries (below certain thresholds), but larger shipments require full ADR compliance.
For air transport, the IATA Dangerous Goods Regulations apply. These international standards have been further tightened in 2025, particularly for passenger aircraft where the transport of lithium batteries is subject to strict restrictions. Cargo transport offers more flexibility, but requires specialised packaging and documentation.
Key changes in 2025 relate to State of Charge (SoC) limits and improved testing procedures for packaging. Batteries may be charged to a maximum of 30% for air transport, whilst different percentages may apply for road transport depending on the specific circumstances.
UN-certified packaging is mandatory for all commercial lithium battery shipments. This packaging must have passed specific tests and bear a UN mark confirming its suitability for hazardous materials.
For defence and industrial applications, such as new defence drones or military equipment, customised packaging solutions are often required that meet both UN requirements and military standards. These combine robust protection with compliance with transport regulations.
Special attention must be paid to transport cases for drones, which often contain multiple batteries. These drone cases must have individual battery compartments that prevent short circuits and provide sufficient insulation. IP 67 protection is often required for military applications to withstand weather conditions and extreme environments.
Labelling must comply with IATA and ADR standards, including:
The transport of lithium-ion batteries in military drones and defence equipment presents unique challenges. These systems often require higher energy densities and must withstand extreme operational conditions, necessitating specific transport measures.
Defence drones often contain multiple battery systems with different capacities and chemical compositions. This requires specialised transport cases that can safely accommodate different battery types without them affecting one another.
Military standards such as MIL-STD-810 impose additional requirements on packaging for defence applications. These go beyond standard UN requirements and include resistance to shocks, vibrations, temperature fluctuations and humidity that may occur in military environments.
For industrial applications, logistical considerations often play a key role. Reusable transport solutions are becoming increasingly popular to reduce costs and meet sustainability targets, making tracking and return logistics essential.
A systematic approach is essential for compliant lithium battery transport. This checklist helps you carry out all critical steps correctly and avoid common mistakes.
Preparation and classification:
Packaging and protection:
Labelling and documentation:
Final check:
By following this systematic approach, you ensure that your lithium-ion battery shipments comply with all relevant safety regulations for 2025. Whether it concerns defence drones, industrial equipment or other critical systems, proper preparation and execution are essential for safe and compliant shipment.
Understanding which ADR, IATA or IMDG regulations apply is an important first step. The greatest challenge, however, lies in translating those requirements into practice. Which rules apply to this specific battery configuration? Which packaging solution is required? And how can you demonstrate during an audit, inspection or handover that all relevant conditions have been met?
Lithium-ion battery transport depends heavily on the configuration and circumstances. The same battery may be subject to different transport requirements depending on whether it is:
Faes therefore does not approach compliant battery transport as an isolated packaging question, but as an integrated challenge involving requirements, engineering, production, documentation and configuration management.
A reliable solution starts with a clearly defined compliance baseline. Together with the customer, Faes identifies which battery is being transported, its condition, the transport mode and the operational circumstances.
We consider not only the general regulations, but also project-specific requirements, including:
The result is a clearly defined set of requirements on which the packaging solution and associated procedures can be based.
Packaging may be technically robust and still be used incorrectly. Examples include incorrect battery positioning, insufficient terminal protection, the use of unsuitable filling materials or improper closure of the packaging.
Faes therefore translates the relevant requirements into a solution that can also be controlled effectively in day-to-day operations. This may include:
This makes compliance less dependent on individual knowledge or experience. The requirements become part of both the physical solution and the process by which the packaging is used.
In defence and industrial applications, it is often not sufficient to simply state that packaging is suitable. The substantiation must be traceable through specifications, drawings, material selections, test results and documentation.
Faes can link the applicable requirements to design decisions and supporting evidence. A Requirements Traceability Matrix may be used for this purpose. For each requirement, it records:
This creates a technical dossier that is useful not only during development, but also for acceptance, audits, tenders and future modifications.
UN 38.3 test documentation, transport approval and packaging tests each serve a different purpose. A battery that has been tested in accordance with UN 38.3 is not automatically approved for every transport scenario or packaging configuration. Faes helps distinguish between these different elements and brings them together in one controlled process. Where formal testing or certification by an accredited test laboratory or specialist body is required, Faes can prepare and coordinate the technical process.
Transport suitability is not a one-time assessment. A change to the battery, battery management system, housing, interior or transport method may affect the original substantiation.
Configuration management is therefore an important part of the approach. Faes can manage drawings, bills of materials, specifications and packaging instructions in a controlled manner. When a change occurs, it can then be assessed:
This prevents packaging from remaining in use for years even though the battery or logistical application has changed.
Faes combines expertise in technical packaging with engineering, production, assembly and system integration. This enables us to go beyond supplying a certified box, case or container.
We help organisations control the entire process: from defining the requirements and developing the packaging to documenting the production configuration, operating instructions and technical substantiation.
For defence and industrial applications, this results in a solution that is not only aligned with the relevant regulations, but is also practical, reproducible and demonstrably controlled.
Are you ready to eliminate risks and ensure full compliance when transporting lithium-ion batteries? Contact Faes today for bespoke advice and certified packaging solutions that meet all requirements for 2025. Our specialists will help you optimise processes, prevent errors and ensure safety. Discover how to make your transport flows safer, more efficient and future-proof.
International regulations are typically reviewed every two years, with minor updates that may be implemented annually. It is essential to monitor quarterly updates via official IATA, ADR and IMDG channels, particularly as changes are often announced only a few months in advance and have an immediate impact on compliance.
Non-compliance can lead to substantial fines (€5,000–€50,000 per violation), transport delays, seizure of goods and even criminal prosecution in the case of serious violations. In addition, insurance claims may be rejected and companies may lose their transport licences, which threatens operational continuity.
Verify that carriers hold valid ADR/IATA Dangerous Goods certificates and request copies of driver training records. Check their UN packaging certificates and ask for their incident history. Conduct regular audits and ensure contractual compliance clauses with a clear allocation of liability.
Standard transport insurance policies often do not cover lithium battery-related damage. Ensure you have specialist dangerous goods insurance that covers thermal runaway, fire and environmental damage. Document all compliance measures carefully, as insurers often require proof of correct procedures when settling claims.
Stop transport immediately and isolate the battery in a safe, ventilated area. Contact the emergency services and the battery manufacturer for specific instructions. Never use water on lithium-ion fires – use Class D fire extinguishers. Document all incidents for reporting to the relevant authorities.
Defence batteries often require export licences and ITAR/EAR compliance in addition to standard UN requirements. Check destination country restrictions and dual-use classifications. Use accredited freight forwarders with security clearance and ensure end-user certificates are in place. Some countries have complete import bans on military battery systems.
Use calibrated multimeters or battery analysers to measure voltage and calculate SoC according to manufacturer specifications. Document measurements with a timestamp and operator identification. Special measurement protocols may apply for defence applications. Retain measurement reports for at least two years for audit purposes and compliance verification.
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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