How to ship lithium and other types of batteries internationally from Australia

Shipping products that contain batteries can feel confusing, and for good reason. With strict lithium battery shipping regulations, one wrong move can lead to serious safety hazards, rejected shipments, or costly delays at customs. From specific battery shipping requirements like UN3481 to packaging, labelling and documentation, there is a lot to know whether you’re a first-time shipper or an experienced exporter.

If you’re sending lithium batteries overseas from Australia, this DHL battery shipping guide breaks down everything you need to know about shipping lithium batteries internationally into a simple and easy to follow step-by-step guide.

Step 1: Check the rules and regulations before you ship

Before you start shipping lithium or other types of batteries internationally, it’s important to understand that how you ship your batteries depends on the type of battery you’re sending and whether it’s installed in a device or shipped separately. Getting this right ensures your shipment stays compliant with battery shipping regulations and avoids unnecessary delays or safety issues.

Are batteries dangerous goods?

Yes, many batteries, especially lithium batteries, are classified as Dangerous Goods under international shipping regulations. This is because they can pose serious fire and explosion hazards if damaged, short-circuited, or exposed to high temperatures.

What kind of battery do I have?

Before you prepare your shipment, you’ll need to know exactly what type of battery you’re dealing with. Here’s a quick guide:

• Lithium-ion batteries (Rechargeable): Found in everyday electronics like laptops, smartphones, power tools, and tablets. These are the most common type used today and are subject to UN3481 shipping requirements when packed with or contained in a device.
• Lithium metal batteries (Single-use): Non-rechargeable batteries found in products such as watches, cameras, calculators, and smoke detectors. These are typically covered under UN3091 and also require specific lithium battery labelling and packaging.
• Standard dry cell batteries: Includes alkaline and nickel-metal hydride (NiMH) batteries commonly found in remotes, flashlights, and toys. These are generally safer but must still be properly insulated and packaged during transport.
• Wet cell batteries: These contain liquid electrolytes and are commonly used in vehicles, electric scooters, and industrial equipment. They must be kept upright and sealed in leak-proof packaging during shipping.

Where to find rules and regulations regarding lithium battery shipping

When shipping lithium batteries from Australia, you must comply with the regulations from the following organisations:

• International Air Transport Association’s (IATA) Dangerous Goods Regulations (DGR)
• Australia’s Civil Aviation Safety Authority (CASA)

Key IATA and CASA requirements include^1,2:

• Correct identification of the battery type and its corresponding UN number.
• Batteries that are swollen, leaking, recalled, or otherwise faulty are strictly banned from air transport.
• Batteries must be protected against short circuits and securely packaged to prevent movement or damage during handling.
• Proper lithium battery shipping label with hazard symbols.
• Anyone preparing or offering lithium batteries for shipment must have Dangerous Goods training and ensure all declarations are accurate and complete.

Regulations preventing the shipping of damaged batteries

Damaged, defective, or recalled batteries pose a serious safety risk during air transport. They can overheat, leak, or even catch fire if exposed to pressure or impact. 

For this reason, all safety policies strictly prohibit the shipping of faulty or swollen batteries under any circumstances. Always inspect your batteries before packing, if they appear corroded, bulging, or leaking, they must not be shipped and should instead be disposed of safely according to local recycling or hazardous waste regulations.

Battery watt hour limits and quantity restrictions per shipment

There are strict limits on battery capacity and quantity per shipment to minimise fire risk during air transport. These are measured in watt-hours (Wh) for lithium-ion batteries and lithium content (grams) for lithium metal types. 

Always verify your shipment’s limits with your logistics provider or customs authority before shipping lithium batteries internationally.

Step 2: Pack your batteries

When transporting lithium or other types of batteries, parcels must be packaged with extra care to prevent short circuits, leaks, or overheating during transit. The exact method depends on the type of battery and whether it’s shipped individually or installed in a device. Below are simple, step-by-step instructions for packing the most common types safely and compliantly under IATA and CASA rules.

How to pack lithium-ion batteries for shipping

If installed in a device:

• Keep the battery installed within the equipment.
• Ensure the device is switched off and cannot accidentally turn on.
• Wrap the device in protective cushioning such as bubble wrap.
• Place in a sturdy outer box with ample filler to prevent movement.
• Attach the correct lithium battery shipping label and mark “Lithium-ion batteries contained in equipment.”

If shipped separately:

• Each battery must be individually protected to prevent contact with other batteries or metal objects.
• Use inner packaging (plastic bags or non-conductive sleeves) for each battery.
• Place inside a strong, rigid outer box lined with cushioning material.
• Include the proper lithium battery labelling (hazard diamond or lithium mark) as required by UN3481 shipping requirements.

How to pack alkaline or nickel-metal hydride (NiMH) batteries for shipping

• Remove batteries from the device whenever possible.
• Cover terminals with tape or caps to prevent short circuits.
• Bundle multiple batteries in individual sleeves or blister packs.
• Use a sturdy outer carton filled with cushioning to keep items secure.
• Clearly label the package contents (e.g. “Dry cell batteries – not restricted”).

How to pack wet cell or lead-acid batteries for shipping

• Only ship if the battery is leakproof and upright.
• Use UN-certified packaging with an acid- or alkali-resistant liner.
• Secure terminals to prevent short-circuiting.
• Use non-conductive dividers between multiple batteries.
• Affix the appropriate Dangerous Goods label and ensure the battery vents face upward.

Step 3: Prepare your documents and labels

Once your batteries are packed correctly, the next step is ensuring all the necessary paperwork and labels are in order.

Essential documents for battery shipments

Depending on your shipment type and battery classification, you may need one or more of the following:

• Dangerous Goods Shipper’s Declaration (DGD): Required when shipping lithium ion batteries internationally.
• Safety Data Sheet (SDS): Outlines the battery’s chemical composition, handling precautions, and emergency response information.
• UN test summary: Confirms the battery has passed mandatory UN safety testing for air transport.
• Air Waybill (AWB): Must accurately describe the contents (e.g. “Lithium-ion batteries contained in equipment – UN3481”).

These documents serve as proof that your shipment complies with lithium battery shipping regulations set by both IATA and CASA.

Additional documents based on import destination

Some countries have extra requirements for importing batteries and electronic products, especially where environmental or product safety laws apply. Depending on your destination, you may also need:

• Battery recycling declarations: Common in the EU or UK under environmental regulations.
• Manufacturer compliance certificates: Confirming adherence to IEC or ISO safety standards.
• Import permits: For large-capacity lithium batteries or medical/industrial devices.
• Product safety or conformity statements: For electronics containing embedded batteries.

Important labels for battery shipments

Every package containing batteries must have the right labels to show what’s inside and how it should be handled. Here’s what to include:

Lithium battery mark

• Necessary lithium battery shipping label for any shipment with lithium batteries
• Shows a battery symbol (one with flames).
• Includes the correct UN number and a contact phone number.
• Must have a red hatched border on a white background.

Class 9 hazard label

• Needed for fully regulated Dangerous Goods or when transporting large shipments of batteries.
• A diamond-shaped black-and-white label with the number 9 at the bottom.

Cargo aircraft only label (if applicable)

• Used when the package cannot travel on passenger aircraft.

Orientation Arrows:

• Mark both sides if the package must stay upright (e.g. wet cell batteries).

Start shipping lithium and other batteries internationally from Australia with DHL Express

Sending lithium batteries overseas from Australia can seem complex, but with DHL Express, it doesn’t have to be. Our customs experts are here to help ensure your battery shipments meet all IATA and CASA safety requirements.

From packaging to handling and customs clearance, we’re here to guide you through every regulation and form needed. Use this DHL battery shipping guide to check packaging rules, labeling requirements, and destination-specific regulations before you send your next shipment.

Create a business account with us to start shipping lithium batteries internationally today.