Your 2025 Guide to Lithium Battery Labels

Lithium batteries are no joke. 

Neither is labeling them.  

These powerful energy sources pose real safety risks during transportation, which is why shipping them comes with strict rules.  If your handling lithium battery shipments, you’ll need proper packaging—and the right thermal labels.

That’s where we come in!

We get it—shipping dangerous goods means navigating a maze of regulations. It’s easy to get lost in the details, and mistakes can be costly.

But don’t worry. By the end of this article, you’ll know exactly how to label lithium batteries the right way, no matter how they’re being shipped.

So why all the hoops when it comes to shipping lithium batteries?

Simple: they pose real safety risks. That’s why lithium batteries are officially classified as dangerous goods. 

If not handled properly, they can create serious electrical hazards—including: 

• Chemical burns
• Electrical shock
• Extreme heat
• Explosions

Lithium batteries need to be stored carefully to handle environmental changes during transit. Defective or improperly stored batteries can short circuit, overheat, or catch fire.

That’s exactly why these shipments fall under the “dangerous goods” category— and why safe storage, packaging, and labeling are non-negotiable.

First things first: you need to know which kind of lithium battery you are shipping. 

There are 2 classification types of lithium batteries: lithium metal and lithium ion.

And depending on the type will determine the specifications and regulations you need to follow.

We could dive into the technical side—lithium compounds, anodes, energy density… but that won’t help you label them. So here’s what matters.

Lithium metal batteries are non-rechargeable. And changes are, you already own a few.

You’ll typically find them in devices like:

• Watches
• Calculators
• Cameras
• Car key tools 
• Defibrillators 
• Remote Controls

Lithium-ion batteries are rechargeable and built to deliver a lot of power in a compact form. That’s why they’re used in so many of the devices we rely on every day.

Some examples include:

• Mobile phones 
• Laptops
• Tablets
• Power tools
• Electric toothbrushes
• Medical equipment

But not all lithium-ion batteries are small. Some are large, high-capacity battery packs used for:

• Electric vehicles
• Backup power systems (UPS)
• Portable power stations
• Solar energy storage
• Electric bikes and scooters

🔋 Shipping Tip: For safety, lithium-ion batteries shipped by air must be at no more than 30% state of charge (SoC). There are also watt-hour limits and strick packaging rules, especially for standalone batteries.

Now that you know the types of lithium batteries, you’ll have a better idea of which labels your package needs.

But how do you clearly identify what kind of battery is inside?

That’s where the UN number system comes in.

Developed by the United Nations, this system standardizes how hazardous materials—like lithium batteries—are classified for transport.

Each lithium battery shipment is labeled with ‘UN’ followed  by a 4-digit number. Think of it like a code that tells carriers two key things:

1. What type of battery is inside (lithium-ion or lithium metal)
2. How it’s packed (as a standalone battery, contained in equipment, or packed with equipment)

Here’s how it breaks down:

• Standalone – Just the battery, shipped by itself
• Contained in equipment – Installed inside a device
• Packed with equipment – Shipped alongside a device, but not installed.

Let’s look at which UN numbers match each type of lithium battery and packaging method.

Lithium-ion batteries will use one of the following UN numbers:

• UN3480 – For lithium-ion batteries shipped on their own (standalone)
• UN3481 – For lithium-ion batteries either contained in equipment (installed inside a device) or packed with equipment (shipped in the same package as a device, but not installed)

Lithium metal batteries are labeled with one of the following UN numbers, depending on their shipping configuration:

• UN3090: For lithium metal batteries shipped alone (i.e., without any equipment).
• UN3091: For lithium metal batteries contained in or packed with equipment.

These distinctions are vital for accurately communicating the contents of your shipment.

🔋 Shipping Note: Lithium metal batteries shipped alone (UN3090) are prohibited as cargo on passenger aircraft. They may only be transported on cargo aircraft, and such packages must display the “Cargo Aircraft Only” label.

Packing Instructions (PIs) are another key part of shipping lithium batteries safety and correctly—especially by air.

They’re created by the International Air Transport Association (IATA) and outline exactly how lithium batteries must be packaged and labeled for transport.

Packing Instructions  vary depending on:

• The type of battery (lithium-ion or lithium metal)
• Whether it’s shipped alone, contained in equipment, or packed with equipment
• The total weight and configuration of the package

For air shipments, refer to:

• PI965 – Lithium-ion batteries (UN3480)
• PI966 & PI967 – Lithium-ion batteries packed with/contained in equipment (UN3481)
• PI968 – Lithium metal batteries (UN3090)
• PI969 & PI970 – Lithium metal batteries packed with/contained in equipment (UN3091)

Each PI is divided into sections, such as:

• Section IA or IB – Fully regulated
• Section II – Only still valid for some PIs

🔋 Shipping Note: Section II is no longer allowed for standalone lithium-ion (PI965) and lithium metal (PI968) shipments by air.

And while it’s not part of IATA’s rules, using durable synthetic labels with strong adhesive is highly recommended to ensure they stay put through handling, temperature shifts, and transit conditions.

When preparing lithium-ion batteries for air transport, it’s essential to consider:

• Watt-Hour (Wh) Rating: Determines the applicable packing instructions and sections.
• State of Charge (SoC): Must not exceed 30% of the rated capacity.
• Gross Weight per Package: Subject to limitations based on the packaging instructions section.

🔋 Note: As of April 1, 2022, Section II of PI965 has been eliminated. All standalone lithium-ion battery shipments must comply with Section IA or IB requirements. Adhering to these guidelines ensures compliance with the latest IATA Dangerous Goods Regulations and promotes the safe transport of lithium-ion batteries.

When preparing lithium metal batteries for air transport, it’s essential to consider:

• Lithium Content: Determines the applicable packing instruction section.
• Gross Weight per Package: Subject to limitations based on the packing instruction section.

🔋 Note: As of April 1, 2022, Section II of PI965 has been eliminated. All standalone lithium-ion battery shipments must comply with Section IA or IB requirements. Adhering to these guidelines ensures compliance with the latest IATA Dangerous Goods Regulations and promotes the safe transport of lithium-ion batteries.

We’ve already covered how dangerous lithium batteries can be when handled improperly.

That’s why safety is critical when transporting them—and why there are strict labeling regulations in place.

Different government and international organizations oversee these rules, and they regularly update them to ensure safe handling and shipping. Some of the key regulatory bodies include:

• PHMSA (Pipeline and Hazardous Materials Safety Administration)
• DOT (Department of Transportation)
• ICAO (International Civil Aviation Organization)
• IATA (International Air Transport Association)

To stay complain, labels must be clearly visible on the outside of the package. Failure to follow labeling rules can lead to hefty fines or rejected shipments.

Also keep in mind: label designs and requirements are updated over time.

Always check the latest regulations before shipping lithium batteries—whether domestically or internationally.

Below are examples of the lithium battery labels required for safe transport and handling.

Battery handling labels are required for certain air shipments, especially under Section IB of the IATA packing instructions. These labels are used when shipping:

• Lithium-ion batteries (UN3480 or UN3481)

• Lithium metal batteries (UN3090 or UN3091)

Lithium battery handling labels include the following information: 

• Minimum size of 100mm x 100mm (4” x 4”)
• Red border around label with a minimum width of 5mm
• Relevant UN identification number 
• Telephone number for additional information
• Battery symbol

If your package is small and cannot handle a full-size lithium battery handling label, the size dimensions can be reduced to 100 mm x 70 mm (4″ x 2.75″). Otherwise, the specifications have to remain the same.

Substances with a Class 9 label are considered miscellaneous dangerous goods—and that includes lithium batteries. 

Fully regulated lithium battery shipments (such as those under Section IA) must display this label on the outside of the package. 

Class 9 dangerous good labels have the following specifications:

• Must be diamond-shaped
• Size: 100mm (4 inches) on each side
• Upper Half: 7 black vertical stripes 
• Bottom Half: A white background
• Bottom Corner: underlined number 9 
• No symbols (such as battery image) are required on this label

It might look a little unusual, but that bright orange label is hard to miss—and that’s the point.

The Cargo Aircraft Only (CAO) label alerts airline personnel that the package cannot be transported on passenger aircraft under any circumstances.

Packages marked with the CAO label must be shipped exclusively on cargo aircraft. This requirement is common for fully regulated lithium battery shipments under Section IA and certain Section IB shipments.

The label’s bold text and color are designed for maximum visibility during the shipping and loading process.

This label is pretty straightforward.

It features a white background with red text that clearly states the package cannot be transported on passenger aircraft.

This label is used when regulations prohibit certain lithium battery shipments from being loaded on passenger planes—typically due to size, quantity, or configuration.

As per the packaging and shipping specifications above, the labels necessary for transporting standalone lithium ion or lithium metal batteries are listed by section below.

As per the packaging and shipping specifications above, the labels necessary for transporting lithium ion or lithium metal batteries packaged with or contained in equipment are listed by section below.

As per the packaging and shipping specifications above, the labels necessary for transporting lithium ion batteries packaged with or contained in equipment weighing more than 5 kg are listed by section below.

You made it! Is your brain overwhelmed yet?

We know labeling lithium batteries is an extensive process. It involves many steps and a lot of information. 

But remember those regulations are in place for safety.

Hopefully this article clears up some of the confusion.

If you’re looking for more information about packing and shipping lithium ion batteries, check out this article.