Originally published as a Nissin guide, updated June 2025. The information presented reflects current regulations and standards as of June 2025. Republished October 2026 with one dated update, noted in the State of Charge section below.
Introduction
Lithium-ion batteries have become indispensable in modern society, powering a vast array of devices from consumer electronics like cell phones, laptops, and power tools to larger applications such as electric vehicles, e-micromobility devices, and grid energy storage systems. Their widespread adoption is largely attributable to their remarkable ability to store a substantial amount of energy within a compact physical footprint.
This high energy density, while a significant advantage, simultaneously introduces a fundamental safety challenge. When this stored energy is released in an uncontrolled manner, it generates intense heat, which can transform internal battery components into highly flammable and toxic gases. This uncontrolled release is the precursor to thermal runaway, a severe chain reaction that can lead to fire, explosions, and the emission of hazardous chemical byproducts.
As industries increasingly adopt higher-capacity battery systems, the consequences of such failures are escalating, underscoring the critical need for robust safety protocols and stringent adherence to established guidelines throughout the entire journey of these powerful energy sources.
The information presented reflects current regulations and standards as of June 2025. However, the regulatory environment is constantly evolving, and as such, some details may change over time.
Key Regulations and Safety Standards Overview
Transporting lithium-ion batteries starts with a comprehensive understanding of the regulatory frameworks and safety standards governing dangerous goods, a term that is used interchangeably with hazardous materials.
- International Air Transport Association (IATA) Dangerous Goods Regulations (DGR): The IATA DGR is the global benchmark for the safe air transport of hazardous materials, including lithium batteries.
- International Maritime Dangerous Goods (IMDG) Code: The IMDG Code governs the safe transport of hazardous materials by sea, with a focus on protecting marine environments.
- United Nations (UN) Manual of Tests and Criteria (UN 38.3): It requires batteries to pass eight specific tests to ensure safety under various conditions, including altitude simulation, thermal cycling, vibration, shock, external short-circuit, impact, overcharge, and forced discharge. The standard applies to all lithium batteries shipped internationally, whether standalone or installed in devices.
- U.S. Department of Transportation’s Hazardous Materials Regulations (HMR) and European Agreement concerning the International Carriage of Dangerous Goods by Road (ADR): These are specific regulations for the classification, packaging, and labeling of dangerous goods, as well as requirements for the construction and operation of vehicles carrying these goods.
- OSHA Hazard Communication Standard (HCS): When a lithium-ion battery or cell does not meet exemptions as an “article” under OSHA’s HCS, the manufacturer or importer is required to classify chemical hazards and provide hazard information to downstream users. This ensures workers are informed about potential chemical exposures and safe handling practices.
- National Fire Protection Association (NFPA) Guidance: NFPA provides crucial guidance for responding to battery failures, including fires and/or explosions caused by thermal runaway.
Packaging, Labeling, and Documentation: A Critical First Step
Labeling
Correct labeling communicates crucial information to all parties involved in shipping and handling. Carriers, customs officials, and emergency responders have to be able to identify the cargo quickly and react appropriately in case of an incident.
Battery and battery products are assigned a unique four-digit UN number and Proper Shipping Name. Packages must clearly display hazard class labels, the UN designation, and other required markings.
Documentation
Documents include the Dangerous Goods Declaration and a Multimodal Dangerous Goods form. Emergency contact information must be included on shipping papers to facilitate a rapid response in case of an incident.
Packaging
The goal when packaging batteries and battery-powered equipment is to minimize the risk of short circuits, overheating, and physical damage during transit. Packing instructions are governed by UN standards and vary depending on whether batteries are stand-alone, packed with, or contained in equipment. The following are some best practices:
- Use strong, approved materials in accordance with the regulations for each mode of transport. At a minimum, batteries and battery-powered equipment should be housed in robust containers that can withstand shocks, vibrations, and pressure changes.
- Separate batteries: Batteries should not come into contact with each other or with conductive materials. Dividers, non-conductive cushioning, and sealed bags are typically used.
- Protect terminals: Terminal ends should be covered to prevent accidental contact, which can trigger short circuits.
- Manage damaged batteries carefully: Batteries that are defective, recalled, or damaged require special handling and may even need different packaging based on their condition.
Important Updates to Transportation Regulations
Each mode of transport is governed by its own regulatory body. For specific guidelines concerning batteries, shippers should consult the IATA Dangerous Goods Regulations (DGR) for air; the International Maritime Organization for sea; and the U.S. DOT for ground transportation.
Global authorities have updated regulations in 2025 for transporting lithium-ion batteries and emerging sodium-ion batteries. Understanding the new rules is critical to staying competitive and compliant in a global market.
State of Charge (SoC) Requirements
The SoC represents the percentage of capacity stored in a battery or energy storage system relative to its rated capacity. Batteries shipped at a reduced state of charge are less prone to thermal runaway.
Previously, only stand-alone lithium-ion batteries were subject to a SoC restriction of no more than 30% when transported on airplanes. Since January 1, 2026, the following SoC requirements have applied to many more lithium-ion battery products, including EVs. According to packing instructions 952, 966, and 967 of the IATA’s DGR, shippers must ensure their lithium-battery products conform to the following restriction. For more information, see the IATA Lithium Battery Guidance Document.
| Battery type | SoC restriction | Approval requirements |
|---|---|---|
| Lithium-ion batteries packed with equipment | No more than 30% of rated capacity (mandatory) | Approval needed for higher SoC |
| Lithium-ion batteries packed with equipment > 2.7 Wh (Watt-hour rating) | No more than 30% of rated capacity (mandatory) | Approval needed for higher SoC |
| Lithium-ion batteries contained in equipment | No more than 30% of rated capacity (recommended) | N/A |
| Vehicles with batteries >100 Wh | No more than 30% of rated capacity (mandatory) | Approval needed for higher SoC |
| Vehicles with batteries ≤100 Wh | No more than 30% of rated capacity (recommended) | N/A |
Electronic documentation
IATA is pushing for a shift towards electronic documentation (e-DGD) for dangerous goods shipments. This move aims to reduce paperwork, minimize errors, and enhance the traceability of dangerous goods.
Pro tip: Technological advancements can rapidly transform the market and necessitate regulatory updates to address new challenges and opportunities. To ensure compliance and relevance, it is critical to work with logistics providers who stay informed and provide the latest guidance.
Trusting Experts for Safe Shipping
Whether you are shipping by air, sea, or road, partnering with experienced logistics providers can help you navigate the complexity and risks associated with lithium-ion battery and EV transport. Not every logistics provider specializes in this field.
Nissin International Transport USA Inc. offers tailored solutions focused on meeting packaging, labeling, documentation, and compliance needs, whether you’re manufacturing, shipping, or using battery-powered products. Nissin is an industry leader in providing high-quality logistics services to the automotive industry, including freight forwarding, customs brokerage, warehousing and distribution, and special shipments. We are part of the global Nissin logistics network, which means you have access to our expertise around the world.
Partnering with experienced professionals helps businesses maintain a proactive approach to complying with complex regulations for shipping any hazardous materials. Meaningful collaboration allows them to move their products safely and efficiently, without falling into costly regulatory traps.
Proper packaging and labeling are not mere details in the world of lithium-ion battery transport. They are critical safeguards that protect businesses, transport workers, and end-users alike.
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Sources
- IATA, Lithium Battery Guidance Document. https://www.iata.org/contentassets/05e6d8742b0047259bf3a700bc9d42b9/lithium-battery-guidance-document.pdf
- PHMSA, Lithium Battery Guide for Shippers. https://www.phmsa.dot.gov/sites/phmsa.dot.gov/files/2024-11/Lithium-Battery-Guide-2024.pdf
- International Maritime Organization, Dangerous Goods. https://www.imo.org/en/OurWork/Safety/Pages/DangerousGoods-default.aspx
