Shipping and Storing Lithium Batteries Safely and Compliantly

May 28, 2024|Material Handling

It is critical to take the proper steps when packaging and transporting batteries.

By: Brian Beetz, Contributor

The use of lithium batteries and battery-powered devices continues to grow. In fact, the global lithium-ion battery market is expected to surpass $150 billion by 2032, compared to approximately $50 billion in 2023 according to Statista.¹

This growth has also brought with it stricter rules around shipping and storing these batteries, which power everything from cell phones and laptops to power tools and electric vehicles (EV). As a result, many organizations have struggled to cope with the impact of expanding restrictions on the supply chain — and to find a safe, compliant and cost-effective approach to packaging and transporting these items.

Companies that manufacture and distribute lithium batteries or devices containing them should look for opportunities to use new and innovative solutions that can streamline the shipping process, improve regulatory compliance and reduce risk.

WHY SHIPPING AND STORING LITHIUM BATTERIES IS CHALLENGING

Solutions for safely transporting large lithium batteries include collapsible, clippable wooden crates.2 Image courtesy of Labelmaster.

Lithium batteries are prone to “thermal runaway,” which results in a ballistic reaction followed by an immediate flame that can propagate to other cells and surrounding packaging. As a result, they are classified as dangerous goods (DG) / hazardous materials (hazmat) and there are strict regulations that must be followed when shipping and handling them. These regulations depend on the size (watt hour) of the battery and condition of the battery (damaged vs. non-damaged).

Storing Lithium Batteries

Storing lithium batteries presents unique challenges because there are both national regulations and unique ordinances to follow, while some countries don’t have specific rules for them. Furthermore, adhering to minimum standards doesn’t guarantee there won’t be a thermal incident. That is why it is critical to take the proper steps to support safe and compliant warehousing of lithium batteries.

For example, lithium batteries should be stored at around 40% charge in a cool, dry and well-ventilated place. It is best to have an area exclusively for storing lithium batteries that is free from any materials that catch fire such as carpet, wood or chemicals. Batteries should be stored in non-flammable containers, such as concrete, metal or packaging designed specifically for storing lithium batteries, large enough that the batteries are not touching each other. It is recommended to have in place a fire detector in the storage area and a fire extinguisher nearby.

Shipping Lithium Batteries

Batteries that are not damaged, defective, or recalled (DDR) and have a watt-hour rating of less than 100Wh (e.g., laptop batteries) can ship as a non-fully regulated shipment by ocean or ground. And batteries with a watt-hour rating of less than 300Wh (e.g., power tools or drone batteries) can ship non-fully regulated by ground when proper labeling requirements are met.

Batteries with a watt-hour rating greater than 300Wh (such as those used in EVs), however, are considered “fully regulated class 9 shipments.” This means they must comply with all hazmat regulations for packaging, labeling, documentation, training and specified shipping methods.

Furthermore, because battery technology and safety standards are different, so are the regulations. Every transport mode requires compliance with a different set of regulations and, in many cases, lithium batteries are prohibited from being transported via air. Different countries also have their own set of DG regulations that must be considered.

Cargo carriers are also a major consideration. Even if your organization is fully in compliance and the training, paperwork, and packaging are perfect, individual carriers ultimately get to decide whether to take your shipment.

All of these factors make shipping and storing lithium batteries require considerable resources, expertise and planning.

NAVIGATING THE COMPLEX LITHIUM BATTERY LANDSCAPE

Next-gen packaging, such as high-density polyethylene (HDPE) transport bins provide safe, reliable, reusable lithium battery transport and storage.3 Image courtesy of Labelmaster.

As the number of lithium batteries being used and shipped continues to rise, more organizations will be forced to navigate today’s complex lithium battery shipping landscape. Fortunately, there are innovative solutions and partners available to address these challenges. Here are some strategies to help ensure compliance and avoid operational disruptions.

Know the regulations that apply to your batteries. Many factors impact how lithium batteries are packaged and shipped. Consider the battery dimensions, weight, power capacity and status (e.g., new, used, a prototype, damaged or end-of-life). Then be aware of the rules and regulations that govern transport (especially any shipping restrictions), including any variations between country or transportation mode and any carrier or company-specific rules, and ensure you have the proper processes and infrastructure in place to maintain compliance across the supply chain.
Use next-generation packaging. Some modern packaging solutions are engineered specifically for storing and transporting lithium batteries and can provide a thermal barrier that mitigates the risk of fires by containing pressure, fire, gasses and projectiles — yet require no use of gel packs, heavy liners or fillers. This makes warehousing and transporting lithium-related items safer, easier and more cost-effective.
Consult an expert. Businesses can simplify the shipping and handling process and ensure compliance by working with a partner who’s done it all before. A trusted partner can help companies understand and navigate every facet of the lithium battery journey — from keeping up with the latest regulations and the packaging process, to transport, training and managing DDR batteries. A partner can also assist in evaluating whether the batteries can be reused or recycled.
Implement proper processes and infrastructure. Ensuring compliance can be challenging, especially for organizations with multiple business units and locations. Establish enterprise-wide processes to make sure every shipment is compliant with the latest regulations — from proper labels and packaging to complete and accurate documentation. DG shipping software can help automate the process while validating each shipment against the latest regulations.
Ensure proper training. Anyone with any part in shipping DG is considered a hazmat employee and must be 49 CFR trained and certified on every aspect of shipping, whether it’s filling out the bill of lading or physically loading the freight. Online, interactive and 3D training can help employees digest complicated DG shipping regulations in a more convenient, interesting and memorable format.

BE PROACTIVE TO KEEP YOUR SUPPLY CHAIN RUNNING SMOOTHLY

As the use of lithium batteries and battery-powered devices expands, so too will the rules for storing and transporting them. Companies that manufacture, distribute and use these items must have adequate processes and tools in place to ensure compliance with these complex, ever-changing regulations and to maintain safe and smooth operations. By evolving their approach to packaging, training and shipping, companies can promote safety and efficiency for anyone handling lithium batteries. WMHS

Brian Beetz is director of regulatory affairs and corporate responsibility at DGeo, the Packaging Division at Labelmaster, the leading provider of products, services and technology for the safe and compliant transport of dangerous goods (DG) and hazardous materials (hazmat). He is a certified Dangerous Goods Safety Advisor (DGSA), has over 20 years of experience in the hazard communication, and environmental, health and safety sectors, and worked in the environmental consulting industry prior to joining DGeo/Labelmaster. Learn more at www.labelmaster.com/dgeo.