How to Ship Batteries Overseas? About Packaging & Restrictions

What Should You Know Before Shipping Lithium Batteries?

As the International Air Transport Association (IATA) and aviation regulators continue to update dangerous goods transportation requirements, businesses shipping lithium batteries, sodium-ion batteries, or related products need to pay close attention to the latest regulations regarding State of Charge (SoC) limits, UN38.3 test documentation, dangerous goods declarations, and packaging requirements.

Failure to comply with these requirements may result in shipments being refused, delayed during customs clearance, or even subject to regulatory penalties. Understanding the latest regulations can help reduce transportation risks and ensure your shipments reach their destination smoothly. This guide covers acceptable battery types, charge limits, and key battery shipping considerations to help you comply with air transport regulations from the outset, properly prepare your shipments, and achieve a smoother international shipping experience.

Can batteries be shipped by air?

The short answer: yes, batteries can be shipped internationally. 

But strict regulations apply. Lithium batteries and similar products are classified as dangerous goods by the International Civil Aviation Organization (ICAO) and the International Air Transport Association (IATA), with strict regulations governing their packaging, labeling, and declaration.

Each type of battery - such as lithium-ion, lithium-metal, alkaline, nickel-metal hydride, and wet batteries - has distinct chemical properties and risks. 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. 

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. For detailed requirements, refer to the DHL Express Lithium Battery Guide.

What you need to get right on the 30% charge limit?

The 30% state of charge (SoC) limit applies to lithium-ion batteries packed with equipment, and to lithium-ion battery-powered vehicles. A lower charge means less thermal energy available if a battery fails in transit, which is the whole point of the rule.

• Packed With Equipment: Lithium-ion batteries packed with equipment (UN 3481, over 2.7Wh) need a verified SoC of 30% or less.    
• Vehicle Rules: Lithium-ion battery-powered vehicles over 100Wh (UN 3556) follow the same 30% limit under PI 952.
• State of Charge standard: Standalone lithium-ion batteries (PI 965, UN 3480) carry the same mandatory 30% limit. Lithium-ion batteries contained in equipment, like a laptop with its battery installed (PI 967), only carry a recommended limit, not a mandatory one. Standalone sodium-ion batteries (PI 976, UN 3551) also carry a mandatory 30% limit, while sodium-ion batteries packed with or contained in equipment (PI 977/978) currently have no regulatory SoC requirement. The mandatory 30% limit for lithium-ion batteries packed with equipment (PI 966) doesn't extend to lithium-metal batteries, which sit under their own packing instructions without a charge limit. And it depends on the shipper to confirm the SoC.

Is your UN38.3 Test Report ready to produce on request?

Shipping a lithium battery in 2026 without a valid UN38.3 Test Report puts your shipment at real risk of rejection. This document proves your battery has passed the required safety tests, and your carrier and forwarder need to be able to see it on request.                   

• Local Authority: If Hong Kong's Civil Aviation Department or your airline asks for proof, you need to produce it straight away.
• Safety Testing: The summary confirms your battery passed the UN 38.3 test series, covering conditions like altitude, thermal cycling, vibration and shock.

How do you pass a Dangerous Goods (DG) compliance check first time?

Most dangerous goods delays happen at the DG compliance check stage, when your paperwork, packaging and labels are checked against the IATA DGR checklist. It isn't a visual spot check once your cargo has already reached the airport. Missing documentation or packaging that doesn't meet spec can trigger a hold, so it pays to get this right before you book.

• Labelling and Marking: Your DG labels, UN number and emergency contact details all need to follow the current IATA DGR specifications.
• Packaging Strength: Your packaging needs to pass the required performance tests, including stacking, to prove it can protect the battery in transit.

Getting these wrong carries real weight in Hong Kong. Under the Dangerous Goods (Consignment by Air) (Safety) Regulations (Cap. 384A), undeclared or mis-declared dangerous goods, including batteries that are improperly classified, packed, marked or documented, can lead to a fine of up to HK$250,000 and up to two years' imprisonment. Confirming your classification and documentation early is the best way to avoid it.

How do you ship the new sodium-ion batteries?

Sodium-ion batteries are generally more stable than lithium, but they're still regulated as Class 9 Dangerous Goods with their own rules.

• New UN Codes: Use UN 3551 for standalone batteries, and UN 3552 for those packed with or contained in equipment.
• Documentation: Your declaration should state "Sodium-ion" clearly, following IATA's naming conventions.
• Packing Instructions: Sodium-ion batteries follow their own packing instructions depending on configuration, so don't assume one instruction covers every case.

DHL’s global network already handles these classifications as standard, so moving to a new battery chemistry doesn't mean rebuilding your shipping process from scratch.

Shipping batteries with DHL Express

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.

You can ship batteries by dropping them off at one of our Service Points, or by arranging for pickup.

Lithium battery shipping and packaging requirements

Lithium batteries fall into two categories: rechargeable lithium-ion and non-rechargeable lithium-metal. In Hong Kong, lithium batteries are regulated for air transport under the International Civil Aviation Organization (ICAO) Technical Instructions, the international baseline for dangerous goods by air².

This is how to package batteries for overseas shipment:

• If batteries are installed in equipment (e.g., laptops, smartphones):
  • Keep the battery installed in the device
  • Ensure the device is fully switched off
  • Wrap the device in bubble wrap and use a sturdy outer box with padding to prevent movement\
• If shipping loose lithium batteries:
  • Protect each terminal with individual packaging
  • Separate batteries using non-conductive dividers to prevent short-circuiting

To simplify sending small electronic devices internationally, DHL treats shipments with minimal lithium batteries as non-restricted goods in specific cases. This includes packages with up to four cells or two battery packs installed in equipment per package, with a maximum of two such packages per shipment. These shipments are generally exempt from lithium battery labelling.

The same exemption may also apply to button-cell batteries installed in devices (e.g., watches with circuit boards), offering added convenience when sending small personal electronics overseas.

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. The following best practices should be observed for shipping of alkaline batteries and dry batteries internationally:

• 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 
• Use ample filler packaging so that the batteries do not shift in transit
• 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. Aside from this requirement, some best shipping practices include:

• Always use UN-compliant leak-proof packaging with acid/alkali-resistant linings and dividers to secure the battery
• Separate multiple batteries in the same packaging with nonconductive dividers
• Secure batteries firmly with vents facing up to prevent overheating or short circuiting
• 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 international shipping services, 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 must include accurate declaration documents, including dangerous goods declarations and battery specifications. Use the MyDHL+ platform to pre-generate these documents and save time, streamlining the process.

Preparing your battery shipment

Don't wait until the courier arrives to check your compliance. Four things to confirm before you book:

• Identify the Code: Your exact UN number, such as UN 3480 for standalone Lithium-ion batteries or UN 3556 for Lithium-ion battery powered vehicles.
• Verify the Charge: Use a calibrated tester to confirm your SoC sits within the limit for your packing instruction.
• Prepare Your Documentation: Your Dangerous Goods Declaration and test report submitted digitally where your forwarder requires it.
• Check the Label and Packaging: Requirements vary by battery type and packing instruction, so confirm the specifics for your shipment rather than working from memory.

Hong Kong also enforces strict documentation accuracy for strategic goods, including certain telecommunications equipment controlled under the Import and Export Ordinance. Accurate paperwork matters most during peak disruption windows like Lunar New Year or Golden Week, when increased shipment volumes can lead to longer processing times and potential customs delays.

Hassle-free battery shipping with DHL’s expert support

If you have questions about how to ship lithium-ion batteries internationally, battery classification, packaging, or documentation, DHL Express service centres can help. Visit a service point and our team will:

• Check your packaging meets requirements for overseas shipping
• Confirm the correct labels are used
• Support you with any required Dangerous Goods declarations

For commercial shippers sending batteries regularly, a DHL business account saves time with pre-configured shipment details and faster creation of compliant waybills and declarations. 

Sign up for a DHL Business Account to streamline battery shipping to over 220 countries and territories, safely and compliantly.

Frequently Asked Questions when shipping lithium batteries (FAQ)