Shipping batteries internationally: Guide to regulations & safe packing

How to ship lithium batteries internationally

The prevalence of battery-powered devices, particularly those containing lithium batteries found in everything from laptops and iPads to medical equipment and power tools, means that many businesses are involved in the shipping process. This cross-border transportation of batteries is subject to stringent regulations at both international and national levels.

At the forefront of international air transport safety is the International Air Transport Association (IATA). Their Dangerous Goods Regulations (DGR) outline comprehensive requirements for the classification, packaging, marking, labeling, and documentation of lithium-ion batteries. Adherence to the latest edition of the IATA DGR is crucial for anyone shipping batteries by air. 

For instance, lithium-ion batteries packed with equipment under UN3481 shipping requirements (lithium-ion batteries packed with or contained in equipment) must follow Packing Instruction 966², which outlines requirements for packaging integrity, labeling, and limitations on watt-hour ratings. Limitations on lithium content also apply, along with strict rules for documentation.

Another example would be the UN3091 shipping requirement, which applies to lithium metal batteries packed with or contained in equipment. These must comply with Packing Instruction 969 (for batteries packed with equipment) or 970 (for batteries contained in equipment). 

Shipping lithium batteries with DHL Express

Because lithium batteries are classified as Dangerous Goods, DHL Express enforces specific restrictions to ensure the safety of its network and personnel.

For lithium-ion batteries, DHL Express generally accepts shipments that meet the following criteria³:

• Each cell must not exceed a watt-hour (Wh) rating of 20 Wh.
• Each battery must not exceed a watt-hour (Wh) rating of 100 Wh.
• Shipments must comply with the relevant IATA Packing Instructions:
  • PI965: Lithium-ion cells and batteries shipped alone.
  • PI966: Lithium-ion cells and batteries packed with equipment.
  • PI967: Lithium-ion cells and batteries contained within equipment.

For lithium metal batteries, the restrictions are based on the lithium metal content³:

• The quantity of lithium metal contained in any cell must not exceed 1 gram.
• The quantity of lithium metal contained in any battery must not exceed 2 grams.

It is imperative to consult the latest IATA Dangerous Goods Regulations for the complete and most current requirements.

Shipping batteries to Japan involves adhering to both international regulations (primarily IATA DGR for air transport) and specific national regulations implemented by Japanese authorities. Key regulatory bodies in Japan that oversee the transportation of dangerous goods, include the Ministry of Land, Infrastructure, Transport and Tourism (MLIT)⁴.

To stay informed about the most recently introduced regulations, it is essential to:

• Regularly consult the official IATA Dangerous Goods Regulations manual and any updates issued by IATA.
• You can also monitor updates from national aviation authorities like the JCAB in Japan or the relevant authority in your destination country before you ship batteries.
• Work closely with your logistics provider, such as DHL Express, as they are responsible for adhering to the latest regulations and can provide guidance on specific requirements.

Types of lithium batteries

Broadly speaking, lithium batteries fall into two main categories:

• Lithium metal batteries and cells: Typically single-use and contain metallic lithium. They are not rechargeable, but they do have a longer life than standard alkaline batteries/cells, making them ideal power sources for devices that are out of reach, such as smoke detectors and computer motherboards. 
• Lithium-ion batteries and cells: These contain lithium, which is only present in an ionic form in the electrolyte. They can be formed into many shapes which makes them ideal for a range of electrical appliances. They have a shorter shelf life than lithium metal batteries, but since they are rechargeable, they are present in many portable consumer electronics such as laptops and smartphones. 

Though widely used, lithium batteries are classified as Dangerous Goods as they're highly flammable. It's important to note that the specific hazard class for lithium batteries under IATA DGR is Class 9 (Miscellaneous Dangerous Goods), with distinctions made based on their type (metal or ion) and packaging configuration, which dictates the applicable Packing Instructions (PI)

For more advice on safely shipping lithium batteries with DHL, click here.

Lithium batteries must also meet specific UN testing requirements, as outlined in the UN Manual of Tests and Criteria, Part III, subsection 38.32. These tests ensure the safety of lithium batteries during transport. Evidence of successful completion of these UN tests is often required as part of the shipping documentation.

Best way to pack and ship lithium batteries

Given their classification as hazardous materials, meticulous packaging is essential for all battery shipments to ensure compliance with international regulations.

It's crucial to understand that the size and weight of your batteries, as well as their final destination, can significantly influence the applicable regulations and packaging requirements for customs clearance. For instance, larger or higher-watt-hour lithium batteries often necessitate more robust packaging and may be subject to stricter quantity limitations per package.

Lithium batteries must also be protected against a short circuit and placed in an inner packaging that completely encloses the battery or cell and then placed in a strong rigid outer packaging³. 

How to pack lithium-ion batteries

Lithium-ion batteries utilize lithium compounds and are often rechargeable, boasting a higher energy density. Due to their potential for overheating and combustion if short-circuited or damaged, they are classified as Dangerous Goods and require more stringent packing to minimize these risks during shipping.

• Pack batteries in inner packaging with the equipment in a strong outer box.
• Secure the equipment to prevent movement and accidental activation.
• Only include batteries needed to power the device, plus up to two spare sets.
• Stay within weight limits: 5 kg for passenger aircraft, 35 kg for cargo-only.
• Do not pack with incompatible Dangerous Goods (e.g., Class 1, 2.1, 3, 4.1, 5.1).
• Use appropriate labels and markings on the package.

Shipping other types of batteries overseas

When shipping other types of batteries to international customers, several key factors dictate the specific requirements for your shipment. The type of battery (e.g., alkaline, NiMH) is a primary determinant, as different battery chemistries have varying hazard levels and thus different regulations. 

Furthermore, how the batteries are packed – whether loose, bundled, or installed within a device – significantly affects the packaging and documentation needed. Finally, the destination country's specific customs regulations can impose additional layers of requirements.

How to ship alkaline batteries

Alkaline batteries are primary, non-rechargeable batteries that generate power through a reaction between zinc and manganese dioxide. While considered less hazardous than lithium batteries, they still need careful packing to prevent short circuits during transit, which could lead to excessive heat generation or leakage.

How to pack alkaline batteries

• Remove the battery from the device to prevent accidental activation.
• Keep it in original packaging if available, or wrap it in bubble wrap.
• Wrap the battery securely to protect terminals from contact.
• Use a double-walled box for sturdy protection during transit.
• Fill empty space with padding material to prevent movement.
• Seal the box tightly with strong packing tape to ensure secure closure.

How to ship dry batteries and nickel-metal hydride batteries

A dry cell battery is commonly used for portable electrical devices like flashlights, remote controls, or portable radios. The dry cell classification includes alkali-manganese, zinc-carbon, nickel-cadmium and other solids. All these battery types still have regulatory requirements, so they must be correctly identified and packed before shipping with DHL.

• Where possible, the batteries should be shipped inside of the electrical device with the terminals protected and the device packed in such a way as to prevent unintentional activation
• In the instance of multiple loose batteries, terminals must be protected by individual packaging and separated within the box by dividers.
• Use plenty of filler packaging so that the batteries don’t move around.
• Use a sturdy outer box/container for all the contents.
• Use plenty of tape to secure the outer box/container shut.
• Attach the correct shipping label clearly to the outside of the box/container.

How to ship wet batteries

A wet cell battery is the original type of rechargeable battery, and thus has a longer shelf life than dry cell batteries. Wet cell batteries get their power from a liquid electrolyte and generate gases, meaning they must be vented and kept upright during transportation to avoid leakage. Wet cell batteries are common in aviation, electric utilities and industrial machinery.

Due to their specific handling needs and regulatory requirements it's best to consult directly with your operations or logistics specialists for safe and compliant shipping procedures. For detailed guidance on shipping wet cell batteries, speak to a logistics expert at DHL Express.

How to ship power banks overseas

Power banks contain lithium-ion batteries, making their international shipment subject to lithium battery regulations. Primarily governed by the IATA Dangerous Goods Regulations (DGR) for air transport, the key factor determining shipping requirements is the power bank's watt-hour (Wh) rating, usually marked on the device.

To pack power banks safely, individually protect each one to prevent short circuits (e.g., with separate packaging or tape over terminals). When shipping multiple units, separate them with cushioning. Use strong outer packaging and apply all required IATA DGR labels and markings.

For shipping power banks to or from Japan, adhere to IATA regulations and check for any specific national requirements from the Japanese Ministry of Land, Infrastructure, Transport and Tourism (MLIT) and the Japanese Civil Aviation Bureau (JCAB).

Battery shipping regulations

Recalled, damaged or defective lithium batteries

Shipping damaged or faulty batteries can be extremely dangerous, with the risk of fire, smoke and fumes. For this reason, any battery that is suspected or known to be defective (swelling, corroding or leaking, for example) is not permitted for shipping within the DHL Express network.

Attempting to ship recalled, damaged, or defective lithium batteries can result in significant penalties. These can include substantial fines levied by regulatory authorities such as aviation safety agencies, as well as potential legal repercussions due to the inherent safety risks involved.

Documentation required to ship batteries internationally

All Shippers are required to read, understand and comply with all regulations applicable to sending shipments of batteries to international destinations.

For shipments of batteries classified as Dangerous Goods, a Dangerous Goods Shipper’s Declaration is a mandatory document. This declaration serves as a formal statement by the shipper, confirming that the contents of the shipment have been properly classified, packaged, marked, and labeled according to the applicable Dangerous Goods Regulations. The Shipper’s Declaration must be completed accurately and signed by a trained and certified individual.

Customers with a MyDHL+ account will be guided through the necessary shipping documentation and labels required for their lithium battery shipment depending on its contents, origin country and destination country. 

The MyDHL+ platform makes it easier than ever to ship online, get quotes, schedule pickups, find locations, track shipments and more! Click here to open an account.

Simplify your international battery shipments

Shipping batteries internationally involves navigating complex regulations where precision is key for safety and compliance. Proper packaging and thorough documentation are essential to prevent delays and ensure your shipments arrive without issue. Staying updated on the latest rules is also crucial.

DHL Express offers significant expertise in handling the intricacies of dangerous goods and restricted items like batteries. Simplify your Japan shipping process and ensure your lithium batteries are transported safely and compliantly. Open a DHL Express business account today to benefit from our experience and streamline your international battery shipments.