Lithium Battery Shipping Boxes

Lithium battery packaging refers to specialized containers and materials used to safely ship lithium metal, lithium-ion batteries and also sodium ion batteries.

Due to the risk thermal runway, proper packaging is critical for regulatory compliance, cargo safety, and protection during transit. These packages are designed to meet U.S. Department of Transportation (DOT) (Road), IATA (air), and IMDG (sea) shipping regulations.

Our UN approved Lithium Battery packaging is suitable for the shipment of Lithium Ion, Lithium Metal and Sodium Ion Batteries via any mode of transport. Our lithium battery packaging solutions are:

• 4G boxes for lithium batteries up to 12kg
• 4DV packaging for lithium batteries over 12kg
• 4GV packaging is also a suitable packaging when use with vermiculite

In the US, shipping lithium batteries and sodium batteries must comply with DOT regulations (49 CFR), as well as model transport regulations such as IATA or air transport and IMDG for sea. Key requirements include:

• Use of suitable UN approved outer packaging
• Appropriate inner packaging
• Appropriate cushioning
• Clear hazard labeling and documentation
• Adherence to the appropriate model regulations and packing instructions

Non-compliance can lead to fines, rejected shipments, or safety risks.

UN 4G lithium battery packaging refers to a tested and certified packaging system made of fibreboard that meets strict performance standards for shipping lithium batteries.

This ensures batteries remain safe and secure in all transport modes.

We offer a wide range of UN 4G lithium battery packaging boxes in various sizes to fit single items or batteries, multiple batteries per box and also batteries packed with or contained in equipment. Custom packaging options are available.

It will depend on numerous factors such as the battery type (UN 3090, UN 3480, UN 3551, UN 3091, UN 3481, UN 3552), battery size, watt-hours, weight and the quantity per shipment and also mode of transportation.

Shippers should refer to the correct packing instructions for packaging regulations or contact our team to ensure you select the correct packaging to meet regulatory requirements.

The main difference is what’s inside and how the battery behaves:

• Lithium metal batteries have lithium metal or lithium compounds as an anode and are non-rechargeable. These are found in things like watches and calculators.
• Lithium-ion batteries don’t use lithium metal. Instead, the lithium is only present in an ionic form in the electrolyte.  These rechargeable batteries can be found in phones, laptops, and electric tools.

From a shipping perspective, these two types follow different safety rules, so it’s important to know which one you’re handling.

This is based on how much lithium is in the battery or how much energy it stores. Most shipping rules follow the United Nations standards to set these limits:

• Lithium metal cells: low-powered if they contain 1 gram or less of lithium
• Lithium metal batteries: low-powered if the total lithium is 2 grams or less
• Lithium-ion cells: low-powered if they are rated at 20 watt-hours (Wh) or less
• Lithium-ion batteries: low-powered if the total is 100 Wh or less

If your battery exceeds those numbers, it’s considered high powered, which means it must meet stricter packaging, labeling, and documentation requirements. Always check your battery’s specs to know where it falls.

Yes. Damaged or defective batteries have even stricter packaging requirements. These must be shipped in appropriate UN approved packaging that falls under packing instruction 908 or 173.185.

Contact us directly for information on compliant packaging solutions if unsure.

We are a trusted provider of compliant lithium battery packaging with:

• UN approved packaging
• Expert regulatory knowledge
• Fast shipping
• Competitive pricing
• Custom solutions

Our packaging meets DOT, IATA, and IMDG requirements for lithium battery transport.