Why EV battery packaging is a ‘critical’ issue
Packaging for electric car batteries is not just any industrial packaging: we are talking about goods with strict requirements due to their potential risk (short circuit, damage, electrolyte leakage, overheating). For this reason, they are usually classified as dangerous goods (Class 9) for transport and require packaging approved in accordance with United Nations (UN) guidelines.
At Embalex, we work precisely with this approach: Class II approved packaging for lithium batteries (e.g. UN 3480/3481 and also UN 3090/3091), including 4A, 4D, 4F and 4G packaging variants depending on the type and characteristics of the battery.
Regulatory framework affecting the packaging of electric car batteries
Although the exact details depend on the mode of transport and the condition of the battery (new, used, prototype, damaged, for recycling), there is a common regulatory framework:
1) UN recommendations and UN 38.3 tests
Globally, the basic framework is the UN recommendations for dangerous goods and, in practice, a cross-cutting requirement is that batteries are tested and documented in accordance with subsection 38.3 of the UN Manual (you will see this cited/carried over by sea, air and road regulations).
What this means in practice: request/manage the test summary and ensure documentary traceability in the logistics chain.
2) ADR/RID (road and rail)
For land transport, ADR/RID defines obligations for protection against short circuits, packaging strength and package conditions. For example, technical guidelines aligned with ADR state that, unless installed in equipment, packages must withstand a fall of 1.2 m without damaging the cells/batteries and must not exceed 30 kg gross weight (with nuances depending on the case).
3) IMDG (maritime transport)
In maritime transport, IMDG requires a performance level equivalent to Packaging Group II and defines Packing Instruction P903, including accepted types of packaging and protection requirements.
In addition, it includes requirements such as a 1.2 m drop (in certain cases) and a gross weight limit of 30 kg (where applicable), together with marking and short-circuit prevention obligations.
4) IATA/ICAO (air transport)
Air transport is the most restrictive mode. The IATA 2026 guidance document states, for example, that UN 3480 (‘loose’ lithium-ion batteries) is prohibited as cargo on passenger aircraft, and that certain shipments require a Cargo Aircraft Only label.
It also sets a very important operational restriction: SoC (State of Charge) ≤ 30% for lithium-ion batteries (UN 3480) in certain cases, unless specifically approved.
5) Regulation (EU) 2023/1542 (life cycle, information and traceability)
Although this regulation is not ‘the transport standard’, it does have an impact on the chain: it reinforces safety, information and traceability requirements, including labelling and the use of QR codes linked to the battery passport (depending on category and implementation deadlines).
Key requirements for ‘approved packaging for automotive batteries’
When referring to approved packaging for automotive batteries, this usually refers to packaging that:
1. They comply with UN performance level (PG II in many cases)
- IMDG P903 requires packaging to comply with Group II performance level.
2. They prevent short circuits and internal movement
- P903 includes protection against short circuits as an additional requirement.
- It also requires that cells/batteries be protected against damage from movement or placement within the packaging.
3. They provide ‘real’ mechanical strength (not just a ‘sturdy box’)
- For land transport, the criterion of a 1.2 m drop without damage is included, in scenarios where applicable.
4. They are adapted to the type of battery (weight, format and condition)
- For heavier batteries, palletised solutions are used to facilitate handling and compliance, with the corresponding approval.
5. They are aligned with the mode of transport
- At Embalex, we offer the possibility of approving and manufacturing specific packaging that complies with ADR, IATA, RID and IMDG, according to the customer's actual logistics flow.
Best practices for packaging electric car batteries (operational checklist)
1) Classify correctly before designing the packaging.
- Is it UN 3480 (loose batteries) or UN 3481 (with/in equipment)?
- Is it a new battery, used battery, battery for recycling, prototype battery or damaged/defective battery? As soon as the scenario changes, the packaging, marking and documentation requirements change. (If in doubt, it is best to consult a dangerous goods advisor).
2) Design the interior to ‘block’ electrical risk
- Non-conductive separators.
- Protection of terminals.
- Materials that prevent metal-to-metal contact.
- No gaps that allow movement.
3) Control movement and impact energy
- Foams/shock absorption (compatible with the risk).
- Customised interior structures (cradles, cells, racks).
- Reinforcements at critical points.
4) If shipping by air: prepare the shipment for extra restrictions
- Be aware of the UN 3480 ban on passenger aircraft and Cargo Aircraft Only requirements where applicable.
- Plan for SoC ≤ 30% where applicable, or obtain approvals if it is essential to exceed this threshold.
5) Marking and documentation: don't let your shipment be rejected at the last step
- Labels/marks according to mode (lithium battery mark, Class 9 labels, etc., as applicable).
- DG documentation (and consistency: what is stated on the paperwork must match the package).
6) Traceability and packaging governance
Implement an internal system for:
- Packaging version control (drawings, materials, instructions).
- Evidence of packaging approval/testing.
- Batch/shipment records and photos of cargo.
Examples of common packaging formats (and when they make sense)
Regulations such as IMDG P903 cover UN packaging formats (e.g. 4A, 4D, 4F, 4G, among others).
At Embalex, we work precisely with approved solutions that fit these formats (selection according to battery, weight, handling and route).
Rule of thumb: first define the risk and the logistics route; then choose the format/material and approval.
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How Embalex helps you with EV battery packaging
At Embalex, we manufacture packaging for electric car batteries with a focus on compliance: Class II approved packaging, adapted to UN 3480/3481/3090/3091, and the possibility of approval and custom manufacturing according to the medium (ADR, IATA, RID, IMDG).
In addition, for heavier batteries, we offer palletised solutions for safer and more compliant handling.
Recommended next step: audit your use case (battery type + condition + route + mode of transport) and design approved packaging that not only ‘complies in theory’ but also works in real-world operations (handling, storage, vibration, transhipments).
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