Overcoming EV lithium battery transport challenges

All signs are pointing up for the electric vehicle (EV) market. Globally, the market for EVs is expected to surge from $105 billion in 2021 to almost $355 billion in 2028. And the number of EVs on the road is expected to increase dramatically from 16.5 million vehicles in 2021 to 125 million by 2030. Consumers are still signing up in droves to purchase new EVs, even though many will have to wait months before they can get behind the wheel.

But these numbers hide a challenge for companies in the automotive industry: the transport of the large format lithium-ion batteries that power EVs. The ongoing transport of new, end-of-life and damaged batteries and cellular module assemblies (CMAs) through the supply chain is a complicated and highly regulated endeavor, and knowing and understanding the regulations and requirements is critical. That’s why every organization in the automotive industry needs a plan for large format lithium-ion battery transport. After all, in today’s rapidly growing EV market, it’s not a matter of if large format lithium batteries will have to be transported, but when.

The challenges of shipping EV batteries
The innate characteristics of large format lithium batteries present a challenge when it comes to transportation, regardless of whether they’re new, used, or damaged, defective or recalled (DDR). EV batteries are large and can weigh anywhere from 40kg to over 400kg, with each battery having its own individual design with different weight distribution points. All this makes the physical handling of EV batteries challenging. Workers often need special training and special equipment just to handle them.

Additionally, lithium-ion batteries pose a fire risk – they are prone to “thermal runaway,” which results in a ballistic reaction followed by an immediate flame that can propagate to other cells and surrounding packaging. Not surprisingly, they are classified as hazardous materials (hazmat)/dangerous goods (DG) and subject to strict regulations for shipping and handling them.

The complex world of lithium battery transport regulations
The rules and requirements for packaging and shipping lithium batteries can vary greatly depending on several factors, such as weight, dimension, power capacity, status, location, and more. Furthermore, because battery technology and safety standards are different, so too are the regulations. Every transport mode requires compliance with a different set of regulations. This includes the 49 CFR for road and rail transport (in the U.S.), the IMDG code for vessel and maritime transport, and IATA Dangerous Goods Regulations (DGR) for air transport.

In many cases, lithium batteries are prohibited from being transported via air. Different countries may also have their own set of DG regulations that must be considered as well.

Large-scale and/or prototype lithium batteries over 35kg can require Special Permits (in the U.S.) or Competent Authority Approval (in Europe) for compliant air transport. Securing a Special Permit or CAA can be a time-consuming process that can bog down your operation if not handled efficiently.

Additionally, batteries with a watt-hour rating greater than 300Wh (such as those used in EVs) are considered “fully regulated class 9 shipments.” This means they must comply with all hazmat regulations for packaging, labeling, documentation, training and specified shipping methods.

Regulations also vary depending on the condition of the battery. And as we’ll see, DDR batteries entail a whole other level of complexity and challenges.

Battery packaging is more than a wooden crate
Unlike most automotive parts, large format lithium batteries often require custom packaging. To be compliant, this specialized packaging must be able to handle the size and weight of the battery being shipped while also passing all UN packaging group requirement testing standards.

If that wasn’t challenging enough, the type of packaging can also vary depending on where, why, and how you’re shipping them. For example, if you are shipping a battery back to the manufacturer for diagnostics or minor repairs you will want packaging that is sturdy enough so it will ensure the battery arrives without damage.

Compliant packaging for large format lithium batteries is complex, with numerous components and materials, and each of these must meet specific standards. For example, for the inner packaging, the battery must be surrounded by cushioning material that is non-combustible, non-conductive and has sufficient absorbent material.

Large format lithium battery packaging is often custom-designed and needs to follow a complex prototyping, constructing and testing process. This can take valuable time, and companies often don’t have the luxury to wait for packaging when they need to transport lithium batteries, especially during a recall. As such, it’s critical to ensure you have the proper packaging before you actually need it.

Recalled batteries add another layer of complexity
While most automakers have standard operating procedures for transporting lithium batteries, recalls are unplanned and challenging events that companies across the supply chain are not typically ready for. As a result, mistakes can happen that cost time and money, and put them at risk.

With large format lithium batteries, it’s essential to have a plan in place to deal with potential issues before they become real problems. That plan encompasses all the basic compliance and transport requirements, along with making sure the organization is prepared for the following items in advance:

- Designing, testing, building and sourcing packaging systems for DDR batteries

- Identifying battery recycling partners and understanding their requirements

- Ensuring regulatory compliance across all transport modes, locations and supply chain partners

Safely and compliantly transporting DDR batteries or managing a recall also requires global regulatory expertise, specialized packaging, and support from supply chain partners and end users.

Don’t take on lithium battery transport alone
As the EV market continues to grow, understanding and managing lithium battery transport becomes increasingly critical. From large recalls to ongoing, daily transport, regulatory compliance, proper packaging, and correct shipping processes – regardless of battery status – requires time and resources that some companies may not have.

The best way to make sure all aspects of large format lithium battery transport are covered is to find a partner who’s done it all before. A trusted partner can help you understand and navigate every facet of the lithium battery journey – from understanding the latest regulations and the packaging process, to transport, training, and managing DDR batteries. Don’t discount the value of taking that burden off the internal team. A partner can also assist in evaluating whether the batteries can be reused or recycled.

Being proactive is key. Companies in the automotive industry should proactively take steps to ensure that lithium-ion batteries are transported safely and compliantly, especially as the EV market continues to grow.