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Lithium batteries have become an integral part of our everyday lives – whether in smartphones, laptops, or industrial applications. However, transporting them carries risks that can lead to mechanical damage, thermal stress, or short circuits, which can lead to overheating and, in extreme cases, thermal runaway. To mitigate these risks, the United Nations regulates the global transport of dangerous goods through the UN Manual of Tests and Criteria. For lithium batteries, the relevant section is UN 38.3, which sets strict safety standards that must be confirmed in the tests described therein.
A significant change affecting air shipments will come into effect on January 1, 2026.
Previous regulation
The following has been in effect since April 1, 2016:
• Lithium batteries shipped alone (UN 3480, PI 965) may only be transported by air freight with a maximum state of charge (SoC) of 30%.
• For batteries installed in devices (PI 967) or packed with devices (PI 966), this 30% limit was previously only a recommendation, not a requirement.
Background: Limiting the charge level reduces the risk of overheating and fire during flight.
What will change from 2026?
From January 1, 2026, the 30% rule will also apply to:
• Batteries packaged together with devices (PI 966), – now mandatory.
This means that in future, all lithium batteries – whether shipped alone or packed with devices – must be charged to a maximum of 30% before being transported by air. Only batteries already installed in the end device may continue to be shipped with a higher charge level.
Comparison: Old vs. New
| Regulation | Until December 31, 2025 | From January 1, 2026 |
| Loose batteries | Requirement: max. 30% SoC | Requirement: max. 30% SoC |
| Batteries in the device | Up to 100% permitted | Up to 100% permitted |
| Batteries with device (included) | Up to 100% permitted | Requirement: max. 30% SoC |
Sönke Zacher, Transport Expert at Jauch, on the new regulation
Question: Mr. Zacher, why is this change so significant?
Sönke Zacher: “The regulation makes air shipping more complex. Previously, the distinction between charge states was based on UN classification: UN3480 (cells or batteries alone) meant a maximum of 30% SoC, and UN3481 (packaged in or with devices) had no restriction. Now, UN3481 includes two different states of charge for air transport. In practice, this is unlikely to cause any major problems, as most major cell manufacturers already produce and ship with a maximum state of charge of 30%. Only where recharging takes place before packaging does the transport route need to be considered.”
Question: What does this mean for companies?
Sönke Zacher: “The rules are being reinforced, and everyone involved needs to take note of them. These regulations exist for good reason – to ensure safety.Unfortunately, there is still a lot of ignorance worldwide and, as a result, many transports are not carried out correctly. As long as nothing happens, it doesn’t stand out. But when incidents occur, it can be really expensive. I Therefore, I strongly recommend compliance with the regulations.”
Further information & Expert Support
Would you like to learn more about UN 38.3 testing?
If you have any questions about shipping lithium batteries, the experts at Jauch are always available to help. Our specialists are happy to assist you in ensuring safe and compliant implementation of the new regulations.
