How to Pack & Ship Lithium Ion Batteries

The dangers of lithium ion batteries are often underestimated—until something goes wrong.

Take the fire in Morris, Illinois, for example. Nearly 200,000 pounds of improperly stored lithium batteries ignited inside an old paper mill, causing a blaze that burned for several days. Toxic smoke and hazardous runoff forced evacuations and contaminated the local environment.

Events like this are why lithium batteries are classified as dangerous goods. When damaged, improperly packaged, or stored incorrectly, they can overheat, catch fire, or even explode.

That’s why strict regulations exist for shipping lithium ion batteries. These rechargeable power sources are common—but also high-risk when mishandled. Whether you’re shipping them alone, packed with equipment, or contained in a device, compliance is critical.

To ship lithium ion batteries safely and legally, you must get three things right:

1. Documentation
2. Packaging
3. Labeling

Lithium ion batteries pose chemical and electrical hazards during transport—especially if they are damaged, improperly packaged, or short-circuited.

To reduce risk, regulations from the U.S. Department of Transportation (DOT), International Air Transport Association (IATA), and major carriers like UPS and FedEx classify lithium batteries as Class 9 dangerous goods and enforce strict packaging and labeling requirements.

There are 3 shipping configurations for lithium ion batteries:

1. Batteries only (UN3480) – shipping standalone batteries or cells not packed with any equipment.
2. Batteries packed with equipment (UN3481) – batteries shipped in the same package as the equipment they power, but not installed in the equipment.
3. Batteries contained in equipment (UN3481) – batteries that are installed inside the device or equipment being shipped.

Each configuration has different rules based on factors like:

• Watt-hour (Wh) rating of each battery or cell
• Number of batteries or cells per package
• Package weight
• Mode of transport (air, ground, sea)
• Carrier-specific policies

These variables determine what’s required for documentation, packaging, labeling, and handling. Some shipments may qualify for exceptions or “Section II” packaging, while others may require full Class 9 labeling, shipper declarations, and UN specification packaging.

Documentation is essential for many types of shipments—but it’s especially critical when transporting hazardous materials like lithium ion batteries.

These documents provide carriers and handlers with the information they need to identify the contents, assess the associated risks, and follow proper safety procedures during transit.

Failure to include the required documentation—or to fill it out correctly—can result in delays shipment refusals, or significant fines.

The specific documents you’ll need depend on:

• Battery configuration (e.g., UN3480 vs. UN3481)
• Battery size and quantity
• Mode of transportation
• Carrier requirements

Common documents may include:

• Shipper’s Declaration for Dangerous Goods (required for many air shipments)
• Lithium Battery Handling Label (if using Section II exception) 
• Air Waybill or Bill o f Lading with the proper markings
• Carrier-specific forms (FedEx, UPS, DHL may require their own documentation)

Always consult the most current version of the IATA Dangerous Goods Regulations and your carrier’s guidelines to confirm what’s required for your specific shipment.

For many air shipments of lithium ion batteries, a Shipper’s Declaration for Dangerous Goods (DGD) is required. This document provides critical safety information to carriers and ensures compliance with international air transport regulations.

Whether you need a DGD depends on the battery type, quantity, and how it’s packed. Most fully regulated air shipments of lithium ion batteries—especially UN3480 (batteries shipped alone)—require this declaration.

Smaller shipments that fall under Section II exceptions may not.

The DGD must be accurately completed and signed by a trained individual. It typically includes:

• Shipper and consignee contact details
• UN number and proper shipping name (e.g., UN3480, Lithium ion batteries)
• Hazard class (Class 9)
• Quantity and net weight
• Number and type of packages
• Any applicable handling instructions
• Air Waybill reference
• A 24-hour emergency contact number (required for U.S. shipments)

Incorrect or missing DGDs can lead to shipment delays, penalties, or refusal by carriers. Always confirm whether your specific shipment requires this document—especially for air transport—and consult the latest IATA Dangerous Goods Regulations and your carrier’s guidelines.

Some carriers, like FedEx and UPS, require a Lithium Battery Handling Document for certain ground shipments. This form confirms that the batteries are undamaged and properly prepared for transport.

It may ask you to check off the battery configuration (e.g., standalone, packed with, or contained in equipment) and confirm compliance with packaging and labeling rules.

You can usually download the latest version directly from your carrier’s website.

A waybill is a transport document that travels with the shipment and outlines its origin, destination, contents, and tracking details. It acts as a contract of carriage between the shipper and the carrier and is commonly used for both air and sea shipments.

Unlike lithium battery compliance documents, the waybill focuses on delivery logistics—helping carriers route and track the shipment accurately. It includes a unique tracking number and contact details for both shipper and receiver.

Waybills are non-negotiable, meaning they can’t be transferred or used as proof of ownership, unlike certain types of bills of lading used in ocean freight.

In short, it’s the shipment’s routing and tracking guide, ensuring it moves smoothly from point A to point B.

Proper packaging is critical when shipping lithium ion batteries. These batteries can overheat, short circuit, or catch fire if damaged or mishandled—making secure packaging essential for safe transport.

To meet carrier and regulatory requirements, batteries must be packaged in a way that prevents movement, accidental activation, and contact with other materials. The packaging should also be able to withstand the normal stresses of transit, such as vibration and impact.

There are two key components to compliant packaging:

• Inner packaging

• Outer packaging

Each plays a specific role in keeping the shipment safe—and we’ll break down both in more detail next.

Inner packaging protects lithium ion batteries from movement and damage during transport—especially as packages are handled by multiple carriers along the way.

To stay compliant, carriers like UPS require batteries to be enclosed in non-conductive materials such as plastic bags or blister packs. Exposed terminals must be covered with tape or non-conductive caps to prevent short circuits.

Inner packaging should be placed in containers made from materials like:

• Plastic
• Fiberboard
• Metal
• Wood

Cushioning is essential. Use dividers, foam, or securing straps to prevent batteries from shifting or damaging each other. When multiple batteries or devices are packed together, each must be individually protected from contact and impact.

Outer packaging protects the shipment from external damage and prevents the release of hazardous contents. It must be rigid, durable, and appropriately sized to prevent crushing or exposure during transit.

For hazardous materials like lithium ion batteries, many carriers require performance-tested packaging—boxes that meet strict durability standards and pass tests like drop and stacking evaluations.

Padded envelopes or poly mailers are generally not acceptable unless they meet specific regulatory criteria. When in doubt, use a sturdy corrugated box with sufficient cushioning inside.

The full delivery and return address must be clearly visible on the outer package. Once packed, the shipment must be properly labeled and marked to indicate it contains lithium batteries.

Lithium battery labels on your packaging are the clearest indication of the hazardous contents being shipped.

Transporters must be made aware of the hazardous contents within a package in order to follow safety precautions. Different designs signify different instructions, therefore using the correct labels and markings quickly communicates this information in an obvious way. 

Shipping Label Instructions:

• How batteries/cells are packaged
• Mode of transportation
• Number of batteries/cells
• Total watt hours
• Total package weight

The mode of transportation will dictate the necessary labels needed. Organizations and agencies, like the IATA and DOT have created complaint safety regulations to help enhance safety provisions through ground and air transportation. Labels should meet strong durability standards for various climate conditions and environments.

The following labels may be necessary for the shipment of your lithium ion batteries. Be sure to check the guidelines with your carrier to ensure packages are properly labeled as more than one can be required.

All labels should be visible on the outside of any boxes or packages.

Packages containing lithium ion batteries must be labeled with a UN number when shipped. This number is part of a rating system developed as a set of standards for shipping and storing hazardous materials. 

For lithium ion batteries, UN 3480 signifies the package contains batteries not being shipped with other products with UN 3481 means the package contains batteries in equipment or packaged with equipment. 

If you’re shipping lithium ion batteries as a standalone (UN 3480) via air, there are new regulations you need to be aware of.

On January 1, 2022, the IATA revised regulations eliminating Section II from PI 965 and PI 968 took effect. These packing instructions had allowed shippers to send packages containing small quantities of  batteries via air transport with fewer restrictions.

Now, lithium battery shipments that fit the criteria for Section II must adhere to shipping using Section IA or IB of the Packing Instruction.

You can read more about the IATA’s regulation update here.

Note, this update also effects standalone lithium-metal batteries (UN 3090)  shipping via air.

As you can see from this article, there are extensive instructions when it comes to shipping lithium ion batteries. These instructions can vary depending on the carrier you use and the mode of transportation. 

Different types of shipments have different rules governing transportation. For example, damaged or defective batteries are restricted to ground transportation only. 

Air and ground carriers have particular rules and regulations set by organizations for safety. It is very important to make sure you’ve taken the time and diligence to meet all of these requirements.

Below are some popular carriers that permit the transportation of lithium ion batteries. They have trained personnel who are certified in their safe handling and regulations. Click the links to find detailed instructions for your desired carrier service.

UPS restricts damaged, defective, or recalled lithium batteries to ground transportation. Customers wishing to ship these faulty batteries must be pre-approved by UPS.

UPS will only accept lithium ion batteries for 48 US states, excluding Alaska, Hawaii, and Puerto Rico. They will not ship them by air.

To view the shipping instructions for lithium ion batteries with UPS, click here.

FedEx offers to ship lithium ion batteries by air, ground or sea. They cannot ship them with any of their SameDay or International offers. Limitations for shipping dangerous goods apply to Alaska and Hawaii, along with many international destinations. 

Special handling fees are applied to dangerous goods shipments along with surcharges in some assessments. FedEx does offer boxes and tubes for lithium battery shipments.

To view the shipping instructions for lithium ion batteries with FedEx, click here.

The shipper is legally responsible for the compliance and safe transportation of lithium batteries with DHL. They will not ship defective, damaged, or recalled batteries.

DHL Express does not accept all types of lithium batteries. The sender must be a pre-approved Express account holder in order to ship them.

To view the shipping instructions for lithium ion batteries with DHL, click here.

Lithium ion batteries packed with or contained in equipment are mailable via USPS air and ground transportation. They will ship to Alaska and Hawaii in limited quantities.

To view the shipping instructions for lithium ion batteries with USPS, click here.

Yes, when it comes to shipping lithium ion batteries the process is extensive and time consuming. As frustrating as it can be, the regulations in place are there for good reason. 

Shipping hazardous materials like lithium batteries poses dangerous threats. It is important that they are packaged, labeled, and mailed in a way that prevents potentially fatal accidents. 

By following these guidelines, you can rest assured your shipments comply with all regulations and will arrive in a safe manner.