Global Shipping Rules for Batteries A Business Guide

This article provides a detailed interpretation of the differences in international express shipping regulations for built-in batteries and accompanying batteries. It covers aspects such as documentation, safety requirements, packaging, declaration, and channel selection. The aim is to assist shippers in complying with regulations and ensuring the safe transportation of battery-related goods. It highlights key considerations for shipping batteries via international courier services, emphasizing the importance of adherence to specific guidelines for dangerous goods.

When your smartphone or laptop needs to travel across borders, the transportation of its battery can pose unexpected challenges. Though small in size, batteries are subject to strict international shipping regulations. The International Air Transport Association (IATA) Dangerous Goods Regulations and United Nations (UN) classification system enforce detailed requirements for battery shipments. Critical differences exist between built-in and loose batteries regarding packaging, documentation, energy limits, and declaration processes. This article breaks down these distinctions to help shippers comply with global standards.

I. Universal Requirements for Battery Shipments

All battery types must adhere to these foundational rules for international transport:

Documentation Compliance

UN38.3 Test Report: Mandatory safety certification for lithium battery air shipments.
Material Safety Data Sheet (MSDS): Details chemical composition and emergency handling procedures.
Airline Approval: Required for high-energy batteries (100Wh–160Wh).
Lithium Content Declaration: Essential for lithium metal batteries.

Safety Fundamentals

Batteries must be undamaged with no leaks or swelling.
Charge state (SOC) ≤30% (mandatory for air transport by 2026).
Devices must be powered off.
No mixing of lithium-ion and lithium-metal batteries.

Labeling & Declaration

External packaging must display lithium battery labels with UN numbers.
Commercial invoices must specify battery type, capacity, and quantity.

II. Built-In vs. Loose Batteries: Key Regulatory Differences

The critical distinction lies in installation status: built-in batteries are factory-installed in devices (e.g., smartphones), while loose batteries ship alongside devices (e.g., camera spares). This difference triggers separate regulatory treatments.

A. Built-In Batteries (Non-Removable/Requires Tools)

Classification: PI967/UN3480 (lithium-ion) or PI970/UN3090 (lithium-metal). Typically treated as general cargo.
Energy Limits:
- Per battery: ≤100Wh (standard consumer electronics)
- Per shipment: ≤500Wh total
- 100–160Wh requires airline approval
- >160Wh prohibited by most carriers
- Lithium-metal: ≤1g per cell, ≤2g per package
Packaging:
- Batteries must be securely fixed within devices
- Devices require cushioning materials
- No electrode insulation needed
Shipping: Eligible for standard DHL/FedEx/UPS channels; declared as "device with built-in battery."

B. Loose Batteries (Packaged With Devices)

Classification: PI966/UN3481 (lithium-ion) or PI969/UN3091 (lithium-metal). Classified as dangerous goods.
Energy Limits:
- Per battery: ≤100Wh
- Per package: Typically ≤2 cells (up to 8 with insulation)
- Lithium-metal: ≤1g per cell, ≤2g per package
Packaging:
- Individual anti-static bags or battery cases
- Electrode insulation required
- Separate from host device in packaging
Shipping: Requires specialized channels; must be declared as "loose lithium batteries" with separate device listing.

Understanding these distinctions is essential for compliant international battery shipments. Professional logistics consultation is recommended for complex cases.