Transporting lithium-ion batteries safely requires more than just robust packaging. The battery type, condition, and mode of transport all determine which packaging and transport requirements apply.
On this topic page, we explain the relevant risks and regulations, how to choose the right packaging solution, and what to consider in practice.
The risks associated with lithium-ion batteries are receiving increasing attention across Europe. In 2025, the European Union Aviation Safety Agency (EASA) published new safety recommendations following a rise in reported safety incidents involving lithium batteries. In the Netherlands, the Human Environment and Transport Inspectorate (ILT) actively monitors compliance with regulations for the packaging and transport of dangerous goods. A shipment that fails to meet these requirements may be stopped before it even leaves.
For businesses, this means that incorrect classification or packaging choices are more than just a safety risk. They can have immediate consequences for your employees, transport planning, costs, and responsibilities as a shipper.
Fire and Explosion Hazards
Thermal runaway can occur at temperatures as low as approximately 80°C. Lithium-ion battery fires have been recorded reaching temperatures above 600°C, with flames extending more than 2 metres. These fires can also release flammable and toxic gases.
Legal Liability
When transporting dangerous goods, consignors, packers, carriers, and other parties each have their own legal obligations. Incorrect classification, packaging, or documentation can therefore also have consequences for your organisation.
Operational Disruptions
During inspections of businesses in the Netherlands, the Human Environment and Transport Inspectorate (ILT) has stopped shipments ready for dispatch until identified deficiencies were resolved. This can lead not only to delays, but also to additional costs for corrective measures, repackaging, documentation, and rearranging transport.
Damaged Batteries Require Different Handling
A damaged or defective battery cannot be treated in the same way as a regular battery. Stricter packaging requirements apply, and air transport may even be prohibited. Incorrectly assessing a battery's condition can therefore directly determine whether a shipment is permitted to be transported at all.
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There is no one-size-fits-all packaging solution for lithium-ion batteries. At Faes, the right packaging solution is therefore always tailored to the specific application. The packaging requirements depend on several factors, including the battery type and specifications, weight and dimensions, battery condition, and mode of transport. It also makes a difference whether batteries are transported separately, contained in equipment, or packed with equipment.
Want to learn more? Find out what to consider for the safe and certified transport of lithium-ion batteries.
Want to find out which custom packaging solution is right for your lithium-ion battery and transport process? Contact our packaging experts.
Lithium-ion batteries are classified as dangerous goods and must therefore be packaged and transported in accordance with specific regulations. The applicable requirements depend on factors such as the battery type, specifications, mode of transport, and whether the battery is transported separately or contained in equipment. The packaging and its internal components must also be properly matched. In a UN-approved packaging solution, they form a single integrated system.
Want to learn more? Download our whitepaper on lithium-ion battery packaging for a practical overview of the key considerations.
Want to understand what these requirements mean for your specific application? Contact our packaging experts.
The difference lies in how the lithium-ion battery is transported. UN3480 applies to lithium-ion batteries transported separately. UN3481 applies when batteries are contained in equipment or packed with equipment. This classification is important because it determines, among other things, the requirements for packaging, labelling, and documentation.
Want to learn more? Find out which regulations apply to UN3480 battery transport or UN3481 batteries contained in or packed with equipment.
Unsure which UN number applies to your battery and what this means for your packaging? Contact our packaging experts.
Transporting a damaged or defective lithium-ion battery requires additional precautions. Damage can increase the risk of short circuits, overheating, and thermal runaway. It is therefore essential to first assess the battery’s condition and determine which packaging and transport requirements apply. Packaging suitable for an undamaged battery is not automatically suitable for a damaged or defective one.
Want to learn more? Read more about the safety risks associated with lithium-ion batteries.
Dealing with a damaged or defective battery and want to know which packaging solution you need? Contact our packaging experts.
The required documentation depends on the battery type, UN classification, and mode of transport. This may include the appropriate transport documents, a UN 38.3 test summary, and, where applicable, a dangerous goods declaration. The information in these documents must also match the packaging and markings used.
Want to learn more? Find out how to correctly document lithium-ion battery shipments.
Want to make sure your packaging, markings, and documentation are fully aligned? Contact our packaging experts.
In this white paper, you will learn why it is crucial to package lithium-ion batteries safely and what risks you can avoid by using the right solutions. You will gain insight into the applicable regulations and practical tools for compliant and safe transport.
Download whitepaper
The regulations themselves are often not the biggest challenge. Problems arise when putting them into practice: what type of battery are you transporting, what condition is it in, which mode of transport are you using, and what packaging is required? An incorrect assumption about any one of these factors can result in a shipment that fails to meet the applicable requirements.
Learn all about standards, risks, and certified packaging solutions.The right packaging depends on the battery type, its condition, and the mode of transport. Our specialists assess your situation and help you determine which requirements apply.
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Lithium-ion batteries can pose a safety risk if they are damaged, short-circuited, or overheated. For this reason, specific ADR regulations apply to road transport, covering classification, packaging, marking, and documentation, among other things. The applicable requirements depend on the battery and how it is transported.
A hard drop can damage a lithium-ion battery, increasing the associated safety risks. The packaging and its internal components must therefore provide adequate protection against shocks and impacts. Drop testing is used to assess how the packaging performs under these conditions.
Specific requirements apply to the air transport of lithium-ion batteries. How the battery is presented for transport, packaged, marked, and documented helps determine whether a shipment is accepted for air freight. A packaging solution suitable for road transport is therefore not automatically suitable for air transport.
