Battery Safety in Logistics & Storage: Expert Insights from Element's White Paper

White Paper: Test & Measurement

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Even after meeting UN 38.3 and shipping regulations, lithium‑ion batteries continue to present hazards in logistics, storage, and end‑use. Fires on highways, at recycling facilities, and on passenger aircraft highlight the consequences of mishandling, improper state of charge, and weak documentation. This white paper explores real‑world incidents, regulatory expectations, and proven best practices that help manufacturers and logistics teams mitigate downstream risk and reinforce safety across the battery supply chain.

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Overview

The white paper “Shipped and Shocking: Battery Safety in Logistics and Storage” by Element Materials Technology Group underscores the critical importance of safety throughout the battery life cycle. By focusing on rigorous testing, inspection, and certification, the document shows how a systematic approach is essential for ensuring safety and reliability in aerospace, transportation, and energy applications.

The paper stresses that testing is an ongoing process that uncovers failure mechanisms at both cell and pack levels. Emily Klein, Lead Failure Analysis Engineer at Element, explains how understanding these mechanisms leads to better product design and performance. The team designs experiments that generate data‑driven insights, driving continuous improvement in safety and reliability.

A key theme is regulatory compliance, particularly UN 38.3 testing requirements, now de‑facto mandatory in the U.S. after PHMSA incorporated them into its regulations. Manufacturers must publish a Test Summary (TS) for lithium cells and batteries, detailing physical attributes and compliance with safety standards. Non‑compliance can trigger fines, shipment delays, and reputational damage.

The white paper also highlights the evolution of safety testing—from a checkbox mindset to a refined approach that uncovers gaps in protocols. Real‑world incidents illustrate the need for proactive safety measures and continuous improvement in testing methodologies.

In conclusion, the document is a comprehensive guide for stakeholders in the battery supply chain, emphasizing rigorous testing, regulatory compliance, and a proactive safety culture. By prioritizing these elements, the industry can reduce risk and ensure that battery products are safe for consumers and the environment, building a safer tomorrow through innovation and informed practices.