Lithium Battery Shipping Rules from China — What Sellers Get Wrong

Lithium batteries are in everything — power banks, e-bikes, handheld tools, wireless earbuds. They're also one of the most regulated cargo types in global freight, and a misstep doesn't just delay your shipment. It can get it rejected at cargo acceptance, impounded at customs, or — in the worst case — trigger a fire incident mid-flight.

Here's what you need to know before shipping.

Why Are Lithium Batteries So Restricted?

Lithium cells are energy-dense and chemically unstable under certain conditions. When cells are damaged, short-circuited, or overcharged, they can enter thermal runaway — a chain reaction that generates intense heat and fire. Aviation authorities treat this as a Category A risk because fires in pressurized cargo holds are nearly impossible to suppress at altitude.

This is why IATA (for air) and IMDG (for sea) have strict rules, and why carriers enforce them hard.

What Is UN38.3?

UN38.3 is the international test standard that lithium cells and batteries must pass before they can be transported. It covers altitude simulation, thermal cycling, vibration, shock, short circuit, impact, overcharge, and forced discharge.

You need a UN38.3 test report for every battery model you ship. This isn't a one-time certification for your brand — it's per cell chemistry and design. If your Chinese supplier swaps the battery manufacturer without telling you, the existing report may no longer apply.

Ask for the report before your first shipment. Reputable factories will have it. If they can't provide one, treat that as a red flag.

The Packing Instructions: PI 965 Through PI 970

IATA divides lithium battery shipments into six packing instructions based on whether the batteries are:

• Cells or battery packs
• Lithium metal or lithium-ion
• Standalone, packed with equipment, or contained in equipment

| PI | Type |

|----|------|

| PI 965 | Li-ion cells and batteries alone |

| PI 966 | Li-ion batteries packed with equipment |

| PI 967 | Li-ion batteries contained in equipment |

| PI 968 | Lithium metal cells and batteries alone |

| PI 969 | Lithium metal batteries packed with equipment |

| PI 970 | Lithium metal batteries contained in equipment |

Each PI has its own state-of-charge limits (usually 30% for standalone cells), quantity limits per package, and labeling requirements. Mixing these up is one of the most common mistakes shippers make.

Why Air Is Restricted — and Sometimes Prohibited

Lithium metal batteries (PI 965, PI 968) are banned from passenger aircraft cargo holds entirely. They can only go as air cargo on freighters, and even then with quantity restrictions.

Lithium-ion batteries shipped standalone (PI 965) are also forbidden on passenger aircraft above a certain watt-hour rating. Consumer-grade power banks typically fall under this.

Batteries that are installed in the device (PI 967, PI 970) can often travel on passenger flights, but the device must be protected against accidental activation and packaged to prevent short circuits.

The practical takeaway: if your product is a battery, not a device containing a battery, expect air to be constrained or unavailable on many carrier routes. Sea freight is often the more reliable option — and see our guide to choosing between air, sea, and rail if you're weighing the tradeoff.

What the Shipper Declaration Requires

Every air shipment of dangerous goods — including lithium batteries that fall under DG regulations — requires a properly completed Shipper's Declaration for Dangerous Goods. This document must:

• Match exactly what's packed
• Include the correct UN number, proper shipping name, packing group, and quantity per package
• Be signed by a person who has passed IATA DG certification training

Errors or omissions on this declaration are grounds for immediate rejection at cargo acceptance. Carriers are not obligated to give you a second chance once the shipment is tendered.

Sea Freight and IMO/IMDG Rules

Ocean carriers follow the IMDG Code (International Maritime Dangerous Goods). Standalone lithium batteries are Class 9 dangerous goods. Requirements include:

• Proper labeling (Class 9 diamond, lithium battery mark)
• Correct documentation in the bill of lading
• Stowage restrictions depending on vessel and cargo

Many ocean carriers require advance notification and DG declaration forms even for PI 967/PI 970 shipments. Check with your freight forwarder before booking.

Common Mistakes to Avoid

• Assuming "contained in equipment" automatically means no DG compliance needed — it still requires correct labeling and limited quantity rules
• Sending a product to your 3PL or Amazon warehouse without declaring the battery hazard class — some warehouses will refuse acceptance or destroy the shipment
• Not checking state-of-charge — many carriers require lithium cells to be shipped at 30% or less
• Using an outdated UN38.3 report after a supplier changed their cell supplier

Get a Rate Before You Commit

Battery surcharges vary significantly between carriers and change with market conditions. Before you finalize supplier pricing, get a freight estimate that includes DG handling fees. The freight estimator can help you model the full landed cost so you're not caught off guard.

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Shipping batteries from China isn't impossible — millions of devices ship every week. But it requires the right documentation, the right packing, and a freight forwarder who actually understands DG compliance. If you're not sure where to start, the freight team can walk you through the requirements for your specific product.