If your business ships products containing batteries internationally, there are some important shipping and packaging considerations you will need to comply with to ensure they arrive there safely and without damage or delay. Read on for a simple guide.
Batteries are a critical component in many modern devices, powering everything from smartphones to electric vehicles. There are many types of batteries that have different requirements when you wish to mail or ship them internationally:
Wet batteries, also known as flooded lead-acid batteries, are commonly found in vehicles and backup power systems. They contain a liquid electrolyte solution, typically sulfuric acid, which enables the chemical reactions necessary to generate electricity. These batteries are known for their affordability and ability to provide high currents.
Nickel-metal hydride (NiMH) batteries are rechargeable batteries often used in portable electronics and tools. They offer a higher energy density than alkaline batteries, meaning they can store more energy in the same space. NiMH batteries are known for their long cycle life and relatively low self-discharge rate, but they can be more expensive than other types.
Dry or alkaline batteries are the most common type of consumer batteries used in everyday devices like remote controls, toys, and flashlights. They use a paste-like electrolyte, usually potassium hydroxide, which makes them more portable and less prone to leakage than wet batteries. Alkaline batteries are available in various sizes and offer a good balance of performance and cost.
Wet batteries, also known as flooded lead-acid batteries, are commonly found in vehicles and backup power systems. They contain a liquid electrolyte solution, typically sulfuric acid, which enables the chemical reactions necessary to generate electricity. These batteries are known for their affordability and ability to provide high currents.
It's crucial to understand that not all batteries are created equal when it comes to shipping. Certain types of batteries, like lithium-ion and lithium-metal, pose higher risks due to their energy density and potential for overheating or combustion. This is why there are strict regulations when it comes to shipping lithium batteries internationally
These regulations often dictate specific packaging requirements, labeling, and documentation to ensure safe handling and prevent accidents during transit. Improperly packaged lithium batteries can ignite, causing fires that are difficult to extinguish and pose a significant risk to the safety of transportation workers and the general public.
For many businesses, the biggest risk is the 'Hidden Dangerous Goods' trap. Lithium batteries are often embedded in devices, from smart textiles to industrial sensors, where their presence isn't immediately obvious. It is your responsibility to audit your entire product line for integrated power sources. Failing to declare a battery because it is 'part of the machine' is a leading cause of shipment rejections and severe regulatory fines.
Other battery types, such as alkaline or nickel-metal hydride (NiMH), are generally considered safer to ship. However, they still require proper packaging and handling to avoid damage and potential short circuits. With regards to what batteries are not allowed to be shipped, damaged or defective batteries should never be shipped due to the increased risk of safety hazards.
There are many considerations and international regulations to adhere to when it comes to shipping batteries internationally. From lithium, dry cell alkaline ,, and nickel-metal hydride to wet cell batteries, each type has unique characteristics and potential hazards, necessitating specific packaging, labeling, and handling procedures to ensure safe transportation.
Though widely used, lithium ion and lithium polymer batteries are classified as Dangerous Goods by the International Air Transport Association (IATA) as they're highly flammable, react sensitively to environmental factors, and can cause fires if damaged.
When shipping goods that include lithium batteries, you are legally responsible for ensuring those shipments comply with the IATA Dangerous Goods Regulations.
Packaging must include the appropriate handling labels as required by lithium battery shipping regulations. All the necessary documentation, such as a lithium battery shipping declaration or a Material Safety Data Sheet (MSDS) must also be included.
If the lithium battery is installed in the equipment it powers:
If the lithium battery is packed with the equipment but not installed:
If you're shipping lithium batteries alone:
Dry cell batteries include alkali-manganese, zinc-carbon, nickel cadmium and other solids. They are sealed and non-vented and therefore less prone to leak. Nickel-metal hydride batteries work in a very similar way, although with a bigger capacity.
While not as strictly regulated as lithium batteries, there are still guidelines to follow when shipping dry cell and nickel-metal hydride batteries internationally.
The safest way to ship batteries is within the device they power. Ensure terminals are protected (e.g., with tape or caps) and pack the device to prevent accidental activation.
If shipping multiple loose batteries, protect each battery's terminals with individual packaging (e.g., plastic bags or caps), and separate batteries within the box using non-conductive (e.g. cardboard) dividers.
Fill all empty spaces within the box with cushioning material like bubble wrap or packing peanuts to prevent batteries from moving and potentially short-circuiting.
Choose a strong, double-walled box or container to hold all the contents securely. Seal the outer box with plenty of strong tape, and attach the correct shipping label clearly to the outside. For dry and nickel-metal hydride batteries, this will typically be a standard shipping label.
If you're shipping alkaline batteries specifically, remove them from the devicee keep them in their original packaging if possible, and wrap each battery individually before placing them in a double-walled box.
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.
Like lithium batteries, there are strict regulations to follow when shipping wet batteries internationally.
An IATA Dangerous Goods label must be attached, along with the correct UN number and shipping name for the particular type of batteries.You must also complete a Dangerous Goods Shipper's Declaration, detailing the contents and potential hazards of the shipment.
Use a strong, rigid outer box or container made of corrugated cardboard or other durable material. It must meet UN specifications for shipping hazardous materials and have an acid/alkali leak-proof liner.
If you're shipping multiple wet batteries, enclose each in its own leak-proof container (e.g., a sealed plastic bag or container) with absorbent material, such as vermiculite or acid-absorbing pads.
Separate them within the box using non-conductive dividers (e.g., sturdy cardboard or foam) to prevent them from touching and potentially short-circuiting.
Fasten the batteries securely in place within the box using packing materials like bubble wrap or foam. Ensure any vent caps are facing upwards to allow for the release of gases and prevent pressure build up.
Fill all remaining empty spaces within the box with cushioning material like bubble wrap or packing peanuts to prevent batteries from moving and potentially causing damage.
Seal the outer box with heavy-duty packing tape, ensuring all seams and edges are completely covered.
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.
When you're shipping lithium-ion batteries by air, it's essential to follow specific regulations regarding their state of charge (SoC). The SoC, which reflects the battery's charge level compared to its full capacity, must not exceed 30% during transit. It's your responsibility to ensure compliance with this rule, as exceeding the limit can lead to safety risks.
Maintaining a State of Charge (SoC) of 30% or less is a mandatory safety buffer required by IATA for UN3480 (Lithium-ion batteries shipped alone). This level significantly reduces the energy available to fuel a fire should a short circuit occur. As a professional shipper, you must implement a verified testing protocol at your fulfillment center to ensure every unit is discharged to the compliant level before being boxed for export.
When shipping lithium batteries, the responsibility for safe and compliant shipping rests with you as the shipper. You are legally obligated to follow all relevant regulations, such as UN3480 and UN3481. Failing to meet with international or local regualtions can lead to serious consequences, including legal liabilities in the event of accidents or incidents involving your shipment. To avoid this, it's crucial to familiarize yourself with and strictly adhere to the UN and IATA guidelines for shipping lithium batteries.
If you're shipping batteries internationally, it's important to be familiar with the regulations that apply. Some types, like lithium batteries, are considered Dangerous Goods, meaning they need special care when packing and labelling to ensure safe transportation. Failing to declare or properly pack these batteries can lead to serious safety risks. Other batteries may be classified as restricted, which means there are specific rules about what types and how many you can send in a single shipment.
It might sound obvious, but when shipping batteries within devices, make sure they are completely powered down and take steps to prevent accidental activation. This may involve taping over power switches or removing batteries and packing them separately. This is crucial to prevent short circuits and potential fires during transit.
Make sure your package is clearly labeled with the right warnings, especially when shipping lithium batteries. These shipments require specific hazard labels and markings to keep everyone safe. Don’t forget to complete the necessary paperwork, like Material Safety Data Sheets (MSDS) and Shipper’s Declarations, as outlined by lithium battery shipping regulations. Proper labeling and documentation not only help you stay compliant, but also ensure that everyone handling your package knows what’s inside and can take the right precautions along the way.
Shipping batteries internationally can feel overwhelming with all the different regulations, safety concerns, and paperwork involved. But don’t worry, you’re not alone. DHL Express has the expertise to guide you through every step. They know how to handle dangerous goods safely and ensure that your battery shipments are fully compliant, no matter where they're headed.
Strategic Compliance Partnership: For businesses in Türkiye, navigating the intersection of local export laws and destination-specific DG (Dangerous Goods) restrictions is a major hurdle. By partnering with DHL Express, you gain access to a global network where every touchpoint is trained in DG handling. From verifying your battery labels to ensuring your documentation meets the latest IATA updates, we act as your compliance shield, allowing you to focus on innovation while we manage the complexities of safe, global transit.
Depending on what you're shipping and where it’s going, DHL Express can walk you through the required documentation, so there’s no guesswork. Plus, with the MyDHL+ platform, everything becomes easier – whether you’re getting quotes, scheduling pickups, tracking shipments, or finding locations. If you're ready to simplify your shipping process, open a business account and get started today.
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