How to Ship Batteries Overseas? About Packaging & Restrictions

Whether you’re shipping batteries for business or sending personal electronic devices like mobile phones, computers, or power banks, ensuring safe and compliant battery transportation is critical. Lithium batteries and similar products are classified as dangerous goods in Hong Kong, and thus, there are strict regulations governing their packaging, labeling, and declaration. 

In this article, we cover acceptable battery types, specific capacity limits, and regulatory requirements to help you meet standards from the outset, preparing battery shipments for a seamless 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 kilograms¹. For detailed requirements, refer to the DHL Express Lithium Battery Guide.

How are lithium batteries classified for shipping?

The two main types of batteries subject to international transport regulations are lithium batteries and lithium-metal batteries. Battery classification for all batteries, including other battery types such as lead-acid or dry cell batteries, determines packaging, labelling and shipping requirements.

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.

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.