Shipping Electronics Safely - Lithium Batteries

Shipping Electronics Safely - Lithium Batteries

Lithium batteries are everywhere. In our laptops, cell phones, and a myriad of other personal electronics. They provide an energy source we could not live without. In this modern age, we take them for granted, and may not fully understand or appreciate the potentiial dangers these devices can contain. Especially if the battery within our favorite electronic gadget happens to be recalled, outdated or damaged in any way. Even leaving a cell phone on the dashboard of your car in the heat of summer can damage the battery in ways that are not readily apparent and can expose you to risk. These energy sources provide high levels of power, making them a potential safety risk during transportation. 

Why Are Lithium Batteries Regulated in Transportation?

Lithium batteries are classified as dangerous goods by International agencies.

If transported incorrectly, they create electrical hazards capable of causing:

  • Chemical burns
  • Electrical shock
  • Extreme heat
  • Explosions

Packages containing lithium batteries must be properly stored to endure changing environmental factors. Improper storage or defective batteries can short circuit, overheat, or start a fire.

Hence the “dangerous goods” category.

And also why you should take the time to safely store, package, and label any mail containing lithium batteries.

Classifications of Lithium Batteries

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.

Lithium cells and batteries are Class 9 (miscellaneous) hazardous materials. There are eight possible descriptions for lithium cells and batteries, depending on the battery chemistry. These descriptions, or proper shipping names, are as follows:

Lithium Metal Batteries

Lithium metal batteries are non-rechargeable. You probably own items that contain these types of batteries.

Some examples of devices that use lithium metal batteries are:

  • Watches
  • Cameras
  • Car alarm activators on your car keys

Lithium-Ion Batteries

One major difference that separates lithium ion batteries from their counterparts is voltage. 

Lithium ion batteries are rechargeable. Because of this, they can only be transported when at a low level of charge (below 30%). 

Some common examples of devices that use lithium ion batteries that you may be shipping are:

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

Lithium Battery UN Rating System 

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

So how do you illustrate the battery material being shipped?

There’s a system in place for this exact purpose: The UN rating system.

It was developed as a set of standards for shipping or storing hazardous materials by the United Nations. 

Here’s a quick breakdown of how it works:

Labels are printed with the letters ‘UN’ and a 4-digit number. 

Think of it like a special code. These numbers clarify 2 types of crucial information: the lithium battery type and packaging method. 

Packaging method refers to how the lithium batteries are being shipped. This can be done in 3 ways:

  1. Standalone
  2. Contained in equipment
  3. Packed with equipment 
Let’s take a look at which UN numbers correlate with their respective battery materials. 

Lithium Ion UN Number

Lithium ion batteries will use labels with one of the following UN numbers:
  • UN3480 
  • UN3481
If you’re shipping lithium ion batteries as a standalone, use a battery label with UN3480. Standalone means the package only contains batteries and nothing else.

If you’re shipping lithium ion batteries contained in or packed with equipment, use a battery label with UN3481. This will generally be the case if you are shipping laptops, tablet computers, and cell phones.

Lithium Metal UN Number

Lithium metal batteries will use labels with one of the following UN numbers:
  • UN3090 
  • UN3091
If you’re shipping lithium metal batteries as a standalone (no other items in the package), use a battery label with UN3090.

If you’re shipping lithium metal batteries contained in or packed with equipment, use a battery label with UN3091.

These slight variations in numbers may seem insignificant, but they are crucial to relaying important information associated with the type of lithium battery contained in your shipment.

We do not recommend that you ship stand-alone batteries. Simply inform your customer that you are unable to transport stand-alone batteries as they are considered hazardous.

Restrictions for Packaging & Shipping

Shipping box with UN3480 and 9 hazard labels

Packing Instructions (PI) are just another piece of the battery label puzzle.
They were created and implemented by the International Air Transport Association (IATA). Specifically, for how lithium batteries must be packaged and shipped for transportation via air.

These instructions refer to information like:

  • Which battery type is being shipped
  • If they are standalone, packed with or contained in equipment
  • The weight limit for the package
Important Note: Please be aware of regulation changes when shipping lithium batteries. Certain carriers have differing policies when it comes to shipping hazardous materials and dangerous goods. It is always best to check with your carrier to make sure your label information matches their policies and are up to date.

Lithium-Ion Batteries 

Instructions for packing and shipping lithium ion batteries include:
  • Wh (watt-hours)
  • SoC (state of charge)
  • Gross weight of batteries per package (in kg)
As a regulation, lithium ion batteries cannot be fully charged when being shipped. 
This is what the state of charge (SoC) refers to. 
The requirement for shipping them puts the SoC at no more than 30%.

Lithium Metal Batteries 

Instructions for packing and shipping lithium metal batteries (i.e. watch battery, or other non-rechargeable battery) include:
  • Amount of lithium in grams
  • Gross weight of batteries per package (in kg)
Because lithium metal batteries are non-rechargeable, they do not have a SoC requirement for shipping. 
Instead they are regulated by how much lithium metal is contained in each shipment.

Lithium Battery Labels & Markings

We’ve already discussed the potential danger lithium batteries pose. 
So when it comes to transporting them, safety is of the utmost importance. 
Regulations have been created for each mode of transport by different government organizations and agencies for this purpose.
They’re responsible for updates and changes to how packages are labeled and shipped. Some of them include:
  • PHMSA (Pipeline and Hazardous Materials Safety Administration)
  • DOT (Department of Transportation)
  • ICAO (International Civil Aviation Organization)
  • IATA (International Air Transport Association)
Labels should be placed wherever visible on the outside package. Large fines or rejected shipments can occur from mislabeling. 
Be aware that new revisions are made to labels over time. Make sure to stay compliant with current regulations for both domestic and international shipments. A good place to start would be the website maintained by the US Department of Transportation, Pipeline and Hazardous Materials Safety Administration, and their guideline for shipping lithium ion batteries here: https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/2022-09/Lithium-Battery-Guide-FN.pdf
Below are examples of lithium battery labels necessary for shipping, handling, and transportation.

Battery Labels

Battery handling labels are required for all air shipments.
They can be preprinted with the necessary information or partially printed, which means the contact information and UN number can be written manually under the graphic. 
Lithium battery handling labels include the following information:

UN lithium ion battery hazard label

  • 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
We've attached a downloadable PDF of a UN3481 label (lithium ion battery contained in equipment) to this article so you can create your own label. Just be sure to print this in color using a durable material that cannot be scratched, torn, and your label must have good adhesion.
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.

Class 9 Dangerous Goods Label

Substances with a Class 9 label are considered miscellaneous dangerous goods. Lithium batteries included. 
Fully regulated shipments require this label. this is required if your lithium ion battery exceeds 100 Wh (watt hours). A typical laptop has a 60 Wh battery for reference. Tablet computers and mobile phones have smaller batteries. So you generally will not need the label below, but it's your responsibility to ensure the battery in the electronic item you are shipping is below 100 Wh and if not, then the label below will need to be attached to the
Class 9 dangerous good labels have the following specifications:
  • 100mm (4 inches) on each side
  • 7 black vertical stripes (upper half of label)
  • A white background
  • A battery symbol
  • A number 9 underlined (bottom corner of label)


Class 9 label

Shipping Damaged Items

Lithium cells or batteries that have been damaged have the potential of producing a dangerous condition and therefore must be transported by ground only. Since you have no way of controlling the carrier and level of service that your customer will select when processing their shipping, it is recommended that you refrain from shipping damaged goods. Shipping internationally is out of the question as the damaged item would require air transport which is strictly prohibited. If you choose to ship an electronic item that has visible signs of damage, be aware that it must be packaged in a certain way, according to these rules:
  • Placing the cell or battery in individual, non-metallic inner packaging that completely encloses the cell or battery. This assumes that you are able to remove the battery from the electronic device, which often is not possible without disassembling the item
  • Surrounding the inner packaging with cushioning material that is non-combustible, electrically non-conductive, and absorbent
  • Packaging the inner packaging in Packing Group I performance level packaging. Note that only one inner packaging may be placed in an outer packaging (i.e., only one cell or battery per package)
  • Marking the outer package with an indication that the package contains a damaged battery, in addition to any other required marks and labels on the package
UPDATE: In June 2022, USPS updated their guidance regarding shipping pre-owned electronics containing lithium ion batteries. Any pre-owned, damaged or defective electronic devices - such as cellphones, laptops, tablets - that either contain or are packed with lithium batteries must be mailed by surface transportation using Parcel Select Ground or USPS Retail Ground, Parcel Return Service or Ground Return Service.

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