Shipping lithium batteries internationally is a complex undertaking, because lithium batteries are classified as dangerous goods and subject to strict safety, packaging, labeling, and documentation rules. Below is a step-by-step guide focused on exporting from China.
1. Understanding Classification & Regulatory Basis
Before you even pack, you need clarity on how the batteries are classified. Lithium batteries generally fall under Class 9 (miscellaneous dangerous goods) and are regulated by frameworks like the UN Model Regulations, ICAO/IATA (for air), and IMDG (for sea).
You must determine whether your batteries are lithium-ion (rechargeable) or lithium metal (non-rechargeable), whether they are shipped alone (UN3480 or UN3090), packed with equipment, or contained in equipment (UN3481 / UN3091).
Another essential requirement is that your batteries have passed UN 38.3 testing, which is effectively mandatory for transport unless the shipment is a very small prototype or test run.
In addition, recent regulatory updates require marking on outside cases with watt-hour ratings, and stricter rules for batteries packed with equipment (such as limiting state of charge to 30 %).
2. Packaging: How to Pack Lithium Batteries Safely
Once classification is settled, packaging is the next major step. Poor packaging is one of the most common causes of incidents (short-circuit, crush, thermal runaway).
Inner packaging / insulation: Each battery or cell should be individually wrapped or placed in a way that prevents contact with conductive materials (e.g. use insulating sleeves, plastic trays, partitions).
Cushioning & impact protection: Use shock-absorbing padding to protect against drops and vibration.
Strong outer box or crate: The outer container should comply with UN standards (drop tests, stacking tests).
Overpack & pallets: If multiple boxes are palletized, you may need an “Overpack” label and ensure each inner box is labeled.
Orientation, stacking, separation: Use orientation arrows, avoid stacking heavy boxes on top of fragile ones, and maintain separation among cells if there is risk of mutual damage.
For air shipments, you must follow the relevant Packing Instruction (PI) under IATA Dangerous Goods Regulations (e.g. PI 965 for batteries alone, PI 966/967 for those packed with/contained in equipment).
3. Labeling & Marking Requirements
Properly marking the package is critical both for safety and regulatory compliance.
UN number & proper shipping name: For example “UN 3480, Lithium-ion batteries” (or UN 3481, etc.).
Hazard class label: Use the Class 9 (miscellaneous) label.
Lithium battery handling mark / label: A special label indicating “Lithium Ion Batteries” with phone number and handling instructions is often required.
Overpack label (if applicable): If the shipment is an overpack (i.e. multiple packages combined), include an overpack sticker.
24/7 emergency contact number: Many regulations require a phone number for emergencies to appear on the label or paperwork.
Watt-hour rating: As of recent rules, especially for batteries larger than 100 Wh, the external marking must include watt-hour rating.
Ensure labels are durable, legible, and affixed to surfaces that will remain intact during handling.
4. Documentation & Declarations
Documentation is often the area where shipments get held up or rejected, so it’s vital to get it right.
Shipper’s Declaration for Dangerous Goods: This is a formal statement declaring the nature of the cargo, UN number, class, number of units, net weight, etc.
Lithium Battery Safety Document / Battery Information Sheet: Some airlines or carriers require a supplemental document describing the battery type, capacity, and safety precautions. UPS+2PHMSA+2
Test summary / UN 38.3 report: You may need to provide the certificate or test summary showing that the battery passed the UN 38.3 tests.
Commercial invoice, packing list, export permit: Standard export documentation, but ensure the battery is clearly described.
Transport document / waybill with hazard notation: On your airway bill or bill of lading, you must include dangerous goods indicators and proper shipping name.
Additional local or national forms: China export rules or the destination country may require extra permits, approvals, or customs filings.
It’s wise to keep a well-organized folder of all documents and include a copy in a document pouch on the outer package.
5. Mode-by-Mode Considerations & Carrier Rules
While many principles are common, each transport mode (air, sea, road) has special rules, and carriers may impose additional restrictions.
Air transport: The strictest rules generally apply. Some lithium battery shipments must go via cargo aircraft only (not in passenger aircraft). The IATA guidance and airline policies must be followed.
Sea / ocean (IMDG Code): In maritime transport, lithium batteries must comply with IMDG regulations.
Road or rail: Overland transportation must follow ADR/RID (in Europe) or relevant national regulations.
Carrier / airline restrictions: Even if your shipment technically complies, carriers (FedEx, UPS, airlines) may have stricter internal rules or bans. Always confirm with the carrier in advance.
State of charge limits: Some regulations or carriers limit the allowed battery state of charge (SoC) to 30% for safety, especially when packed with equipment.
Quantity and weight limitations: There are maximum allowed amounts per package or per shipment under certain packing sections.
6. Operational Tips, Risks & Best Practices
Work with experienced freight forwarders: They often already understand dangerous goods procedures and airline policies.
Audit & training: Ensure your packaging and operation staff are trained on dangerous goods handling and aware of the risks.
Inspect incoming batteries: Reject batteries with visible damage, leakage, or swelling.
Insurance & contingency planning: In the event of damage or fire, have emergency response and insurance in place.
Pre-check & pre-approval: Submit your packaging plan, sample labeling, and documentation to the carrier or airline for pre-approval before mass shipping.
Track regulation updates: Rules on lithium battery transport change periodically, so always use the latest IATA/IMDG and local regulations.
Thoughts
Shipping lithium batteries from China to foreign markets is challenging, but manageable with the right preparation. By classifying your battery correctly, using certified packaging, labeling with care, preparing precise documentation, and coordinating with carriers, you can greatly reduce risk and avoid regulatory delays. Always stay current with global rules, and when in doubt, consult a specialist in dangerous goods logistics.
