How to Ship Batteries Overseas? About Packaging & Restrictions

Can Batteries Be Shipped by Air?

There are various types of batteries, including lithium-ion, lithium-metal, alkaline, nickel-metal hydride, and wet batteries. Each has distinct chemical properties and risks, so it’s essential to identify the battery type and follow corresponding packaging and labeling regulations before shipping. Lithium batteries, due to their high energy density and flammability, are classified as dangerous goods by IATA, while alkaline batteries, though lower risk, still require proper packaging to prevent short-circuiting. Whether for personal or commercial shipments, senders are legally responsible for ensuring compliance with destination country regulations and international air transport rules.

DHL Express accepts common battery types such as lithium-ion, lithium-metal, alkaline, and nickel-metal hydride batteries, but each comes with specific restrictions:

• Lithium-ion batteries installed in equipment must not exceed 20 watt-hours (Wh) per cell or 100 Wh per battery pack.

• Lithium-metal batteries must have a lithium content below 1 gram per cell or 2 grams per battery pack.

Notably, regulations differ for loose batteries versus those packed with equipment. Each waybill is limited to a maximum of two compliant packages, with each package’s net weight not exceeding 5 kilograms. Always verify battery specifications to ensure they meet DHL’s acceptance standards. For detailed requirements, refer to the DHL Express Lithium Battery Guide and the IATA Lithium Battery Guidance.

Lithium Battery Shipping and Packaging Requirements

Lithium batteries are divided into rechargeable lithium-ion batteries and non-rechargeable lithium-metal batteries, both subject to stringent regulations. For equipment containing lithium batteries (e.g., mobile phones or laptops), ensure the device is fully powered off and wrapped in bubble wrap to prevent accidental activation during transit.

For loose lithium batteries, each terminal must be individually packaged and separated with dividers to prevent short-circuiting. DHL Express requires pre-approval for shipping lithium batteries, ensuring the account holder is adequately trained and complies with applicable regulations and DHL policies.

To simplify shipping small electronic devices, DHL allows shipments with minimal lithium battery quantities—up to four cells or two battery packs installed in equipment per package, with a maximum of two such packages per shipment—to be treated as non-restricted goods, exempt from lithium battery labeling. This also applies to button-cell batteries installed in devices (e.g., watches with circuit boards), offering convenience for shipping small personal electronics.

Alkaline and Dry Battery Packaging Requirements

Dry batteries, such as alkaline, zinc-carbon, or nickel-metal hydride, are less flammable but still require careful handling. Retain original packaging whenever possible. For loose batteries, insulate terminals with non-conductive material and use sturdy double-layered cardboard boxes filled with cushioning material to prevent movement. Separate multiple batteries with dividers to avoid contact and short-circuiting. Seal the outer box with strong tape and clearly label it with “Dry Battery” and the shipping address for easy identification and processing during transit.

Wet Battery Handling and Labeling Requirements

Wet batteries, such as lead-acid batteries used in vehicles or industrial equipment, contain liquid electrolytes and must remain upright with adequate ventilation during transport to prevent leaks or gas buildup. These batteries require UN-compliant leak-proof packaging with acid/alkali-resistant linings and dividers to secure the battery. The outer packaging must display a “Dangerous Goods” label, orientation arrows, and a shipper’s declaration form to ensure proper handling per dangerous goods protocols. For questions about wet battery shipping, contact the DHL customer service team for professional support.

Prohibited and Defective Batteries

Damaged, swollen, leaking, or recyclable batteries are strictly prohibited from DHL’s network, as they pose significant fire or short-circuit risks to personnel and transport vehicles. If shipping equipment with a defective battery (e.g., a swollen laptop battery), the battery must be removed before shipping. All battery shipments require accurate declaration documents, including dangerous goods declarations and battery specifications. Using the MyDHL+ platform to pre-generate these documents can save time and streamline the process.

Hassle-Free Battery Shipping with DHL’s Expert Support

If you have questions about battery classification, packaging, or documentation, DHL Express service centers offer professional assistance. Visit a service point, and our team will verify packaging compliance, assist with correct labeling, and complete necessary dangerous goods declarations. For commercial clients frequently shipping batteries, we recommend opening a DHL business account to access MyDHL+ platform features, enabling pre-configured shipment data, quick generation of compliant waybills, and dangerous goods declarations for enhanced efficiency and accuracy. Sign up for a DHL business account today to experience a streamlined process designed for commercial shippers, ensuring your battery shipments reach over 220 countries and territories safely and compliantly.