Lithium batteries have become an indispensable part of modern life, powering everything from our smartphones and laptops to electric vehicles and industrial equipment. The global lithium ion battery market is expected to grow from $36.7 billion in 2019 to $129.3 billion by 2027, at a CAGR of 18% during the forecast period.^1
With such widespread use, it‘s no surprise that shipping lithium batteries is a common need for many businesses and individuals. However, the process can be complex due to the hazardous nature of these batteries. Shippers must navigate a web of regulations and requirements to ensure compliance and safety.
As a leading carrier, FedEx transports a significant volume of lithium batteries every day. In this comprehensive guide, we‘ll explore everything you need to know to ship lithium batteries with FedEx like a pro. We‘ll cover:
- Types of lithium batteries accepted by FedEx
- Packaging and labeling requirements
- Required documentation
- Quantity and weight restrictions
- Differences between FedEx Express and FedEx Ground
- Special considerations and expert tips
By the end of this article, you‘ll be equipped with the knowledge and resources to confidently ship lithium batteries while staying on the right side of the regulations. Let‘s get started!
Types of Lithium Batteries Accepted by FedEx
FedEx accepts two main categories of lithium batteries:
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Lithium ion (Li-ion) batteries and cells: These are rechargeable batteries commonly found in consumer electronics like cell phones, tablets, laptops, and digital cameras. They‘re also used in some medical devices, power tools, and electric vehicles. Lithium ion batteries are generally safer and more stable compared to lithium metal batteries.
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Lithium metal batteries and cells: These are non-rechargeable batteries often used in devices like watches, hearing aids, some medical devices, and certain industrial applications. They tend to have higher energy density but also higher risk compared to lithium ion batteries.
Within each category, batteries may be shipped on their own (fully regulated), packed with equipment (partially regulated), or contained in equipment (also partially regulated).
According to a survey by Packaging Digest, 28% of respondents ship standalone lithium batteries, 37% ship batteries packed with equipment, and 61% ship batteries contained in equipment.^2
It‘s crucial to correctly identify your battery type and configuration, as this determines the specific regulations and requirements that apply.
FedEx Express vs FedEx Ground
The shipping service you choose also impacts the lithium battery shipping rules. Here‘s a breakdown of the key differences:
FedEx Express (Air):
- Accepts both lithium ion and lithium metal batteries
- More stringent regulations due to air transport risks
- Standalone lithium metal batteries are forbidden on passenger aircraft, must be labeled Cargo Aircraft Only
- Lower quantity limits for standalone batteries
- Requires shipper‘s declaration for dangerous goods for standalone batteries
- Certain countries have additional restrictions or prohibitions
FedEx Ground (Road):
- Accepts both lithium ion and lithium metal batteries
- More lenient regulations compared to air
- No passenger aircraft restrictions
- Higher quantity allowances for standalone batteries
- Electronic shipper‘s declaration is acceptable
- May be a better option for large or bulk battery shipments
Ultimately, your choice of shipping service will depend on factors like speed, cost, and the specifics of your batteries. A 2020 survey found that 53% of companies prefer shipping batteries by ground, while 47% prefer air shipments.^3
Packaging Lithium Batteries for FedEx
Proper packaging is essential to prevent short circuits, damage, and thermal events during transit. FedEx requires that lithium batteries be packaged in strong rigid outer packaging that completely encloses the batteries.
Some key packaging points:
- Use original manufacturer packaging if possible
- Separate and protect battery terminals with non-conductive caps, tape, or plastic bags
- Secure batteries to prevent shifting and movement
- Place absorbing cushioning material between batteries and equipment
- Make sure devices are turned off completely
- Use tape to prevent accidental activation of switches
Standalone lithium batteries have additional packaging requirements. For example, FedEx Express shipments of loose lithium metal batteries must be placed in plastic bags and then in a UN specification packaging.^4
Failing to properly package batteries is a common mistake. In a survey of logistics professionals, 42% cited packaging errors as the top challenge in shipping lithium batteries.^5
Labeling Lithium Battery Shipments
Correct labeling alerts handlers to the presence of lithium batteries and communicates key information. The main labels required are:
- Lithium Battery Mark: Indicates the package contains lithium ion or lithium metal batteries. Must include UN number, emergency phone number, and state if batteries are contained in or packed with equipment.
- Cargo Aircraft Only Label: For standalone lithium metal batteries shipped via FedEx Express, as they‘re forbidden on passenger planes.
- UN Numbers: Lithium batteries must be marked with the appropriate UN identification number:
- UN3090 for lithium metal batteries
- UN3091 for lithium metal batteries packed with or contained in equipment
- UN3480 for lithium ion batteries
- UN3481 for lithium ion batteries packed with or contained in equipment
Labels must be durable, legible, and prominently displayed on the package exterior. Incorrect labeling is another frequent mistake, with 32% of logistics professionals reporting mislabeling as a major challenge.^5
Documentation for Lithium Battery Shipments
In addition to labels, certain lithium battery shipments require a dangerous goods declaration. This is a legal document where the shipper certifies that the batteries have been properly classified, packaged, marked, and labeled.
FedEx Express requires a hardcopy declaration with red hatchings for standalone lithium battery air shipments. FedEx Ground accepts electronic declarations for these shipments.
Batteries packed with or contained in equipment typically do not require a declaration, but may need a lithium battery transport document included in the package.
Over 25% of companies say that properly completing dangerous goods declarations is their biggest challenge when shipping lithium batteries.^6 Partnering with a dangerous goods expert can help ensure documentation accuracy and completeness.
How Many Lithium Batteries Can I Ship with FedEx?
Lithium battery shipping regulations include strict quantity limits, especially for air transport. The limits vary based on battery type, configuration, and Watt-hour (Wh) rating.
Here are a few key quantity rules for FedEx Express:
- Standalone lithium ion batteries are limited to 35kg per package for cargo aircraft. On passenger aircraft, only batteries not exceeding 2.7Wh are permitted, with a 2.5kg package limit.
- Standalone lithium metal batteries are forbidden on passenger aircraft entirely. Cargo aircraft shipments are limited to 35kg per package.
- Lithium ion batteries packed with or in equipment have a 35kg package limit for passenger and cargo aircraft. Batteries must not exceed 100Wh.
- Lithium metal batteries packed with or in equipment have a 5kg package limit for passenger aircraft and 35kg for cargo aircraft. The lithium content must not exceed 2g per battery.^7
FedEx Ground has higher allowances, with up to 70kg permitted for larger standalone battery shipments.
It‘s important to stay within these limits, as quantity violations are a leading cause of lithium battery shipping fines and penalties. A logistics industry survey found that 18% of respondents had been fined for violating lithium battery shipping rules.^5
Special Considerations and Expert Tips
A few final considerations to keep in mind:
- Damaged, defective or recalled batteries are forbidden for air transport. For ground transport, these batteries may be shippable with special packaging and approvals.
- International shipments may have additional country-specific requirements, with some countries prohibiting lithium battery shipments altogether. The FedEx Global Lithium Battery Compliance Tool can help determine country rules.^8
- Never misdeclare a shipment as not containing lithium batteries when it does. This is illegal and can result in severe penalties.
- Automated solutions like the FedEx Ship Manager can help streamline the shipping process and reduce manual errors.
- Training is key. FedEx offers online and in-person dangerous goods training to help shippers stay compliant. Over 50% of logistics professionals believe better training is the solution to lithium battery shipping challenges.^5
When in doubt, always reach out to the experts. The FedEx Dangerous Goods Hotline is available at 1.800.GoFedEx for any lithium battery shipping questions.
The Future of Lithium Battery Shipping
As lithium battery use continues to grow, shipping regulations will likely evolve as well. The IATA updates its lithium battery shipping guidelines annually, with the latest version effective from January 1st, 2021.^9
Potential future developments include:
- Stricter packaging and labeling requirements
- Lower quantity limits, especially for air shipments
- More countries adopting restrictions or bans
- Increased enforcement and penalties for violations
- Greater adoption of fire-resistant packaging materials
To stay ahead of the curve, it‘s crucial for frequent lithium battery shippers to stay informed on regulatory changes and best practices. Subscribing to FedEx Dangerous Goods Alerts and attending industry events can help you stay up-to-date.
Key Takeaways
Shipping lithium batteries with FedEx is complex but manageable with the right knowledge and preparation. Remember to:
- Correctly identify your battery type and configuration
- Choose an appropriate shipping service based on your needs
- Package batteries to prevent short circuits and damage
- Apply proper labels including the lithium battery mark and UN number
- Include a dangerous goods declaration when required
- Comply with quantity and weight restrictions
- Consider special circumstances like country rules and damaged batteries
- Reach out to FedEx Dangerous Goods experts for guidance
- Stay informed on regulatory updates and best practices
By following these guidelines and leveraging expert resources, you can maintain lithium battery shipping compliance and keep your supply chain moving smoothly.
Now you‘re ready to power up your lithium battery shipping strategy with FedEx!
