Managing the air cargo risk of lithium batteries
Industry stakeholders face a central question—how can the global aviation system transport lithium-ion batteries safely at scale?;
Global demand for electronics, e-bikes, and electric vehicles has shifted more lithium battery consignments into air cargo channels. Shipments once confined to maritime freight are now moving by air to meet tight delivery schedules.
The International Civil Aviation Organisation (ICAO), the International Air Transport Association (IATA), and national regulators such as the Federal Aviation Administration (FAA) play a central role in defining airborne safety standards for lithium batteries. Their increasingly strict measures reflect both economic and safety imperatives. Inadequate packaging, undeclared cargo, or poor training can cause catastrophic losses of aircraft and cargo, placing both operators and consumers at risk.
Understanding the hazard in flight
Lithium-ion batteries present unique hazards when transported. Inside each cell, energy is stored through chemical reactions that, if uncontrolled, can spiral into thermal runaway. When a cell is damaged, overcharged, or exposed to excessive heat, its internal temperature may rise sharply. This increase accelerates further chemical reactions, generating even more heat and triggering potential ignition. Once ignited, a single cell can ignite adjacent ones, creating a chain reaction capable of intense heat and smoke release.
The FAA recorded dozens of incidents in which aircrew reported smoke, flame, or heat from devices or cargo containing lithium batteries. In August 2024, Mobilesentrix, a Virginia-based company, shipped lithium-ion batteries via FedEx but failed to declare them as hazardous or package them properly, causing heat from the poorly packed units to fuse the cells together.
These risks multiply when shipments are undeclared or mislabelled, denying cargo handlers the chance to apply correct safety measures. Even small consumer devices remain a hazard when faulty or counterfeit components are involved.
We ensure lithium batteries are properly declared, handled, and transported in full compliance with regulations.
Bachi Spiga, DHL Express
The regulatory landscape governing lithium-ion air transport continues to evolve. Under ICAO and IATA rules, lithium batteries fall within the Dangerous Goods classification, demanding strict packaging, labelling, and documentation. The FAA in the United States has stepped up enforcement, levying six-figure penalties on violators for breaching hazardous materials laws. The Civil Aviation Administration of China (CAAC) has likewise intensified oversight, banning uncertified power banks on domestic flights unless they display a valid China Compulsory Certification mark.
Such actions signify a broader shift in global enforcement. Non-compliance can result not only in fines and shipment delays but also in reputational damage and potential flight diversions. Regulators are also mandating hazardous materials training and encouraging emergency preparedness across all transport stages. Yet achieving consistent compliance remains challenging given the cross-border nature of cargo networks.
Airlines and ground handlers hold the operational responsibility for screening and accepting lithium battery shipments. Their safety frameworks rely on inspecting hazardous materials before acceptance, verifying declarations, and using tools such as X-ray imaging or data-driven detection systems. Packaging rules require UN-certified materials that isolate cells, absorb impact, and prevent spark propagation. Staff training remains at the core of compliance. The FAA’s competency-based approach emphasises matching training to employees’ roles, ensuring every handler, loader, and supervisor understands their exposure points.
Yuta Takahashi, manager of global marketing at ANA Cargo, said the carrier undertook a major safety initiative after a series of global battery incidents. “ANA became the first Japanese carrier to achieve IATA CEIV Lithium Batteries Certification in December 2024,” he noted. “Our handling processes, staff training, specialised equipment, and quality control systems meet IATA’s stringent requirements.” He added that ANA has also introduced measures to “minimise handling damage and mitigate temperature rises when batteries are stored for extended periods.”
In the Middle East, Bachi Spiga, vice president of network operations for DHL Express, said that compliance is rooted in strict adherence to ICAO and IATA regulations. “Since DHL owns and leases aircraft, every lithium shipment must comply fully with both ICAO and IATA Dangerous Goods requirements,” he said.
DHL uses a proprietary screening tool known as the Undeclared Dangerous Goods Notification system, which scans electronic documentation to identify items needing physical inspection. “The system analyses shipment descriptions to flag categories requiring investigation and helps prevent undeclared dangerous goods from entering our network,” Spiga added. DHL also applies the competency-based training and assessment model, ensuring employees are evaluated on their specific job functions. Freight forwarders play an equally critical role.
Kathy Liu, vice president of global sales and marketing at Dimerco Express Group, said her firm operates under a “zero-tolerance” policy toward non-compliant air cargo. “Every lithium-ion battery shipment undergoes a multi-point compliance check, including verification of the Shipper’s Declaration and MSDS (Material Safety Data Sheet),” she said. “We act as a technical partner to shippers, advising on UN classification, packing groups, and compliant packaging standards.” Liu also highlighted technology’s role: “With our self-developed digital platform, MyDimerco, customers gain 24/7 visibility and can set personalised milestone alerts to monitor shipments proactively.”
Our focus is a ‘zero-tolerance’ policy for non-compliant documentation or packaging, ensuring only fully regulated cargo enters our network.
Kathy Liu, Dimerco Express Group
Despite these frameworks, lapses still occur. The FAA has linked a number of fires in the United States to shipments that were either mislabelled or not reported. In 2025, Mokwheel Bikes was penalised for improper documentation, a common issue among small exporters.
Regulations must address not only cargo but also personal devices within the cabin. China’s decision to remove uncertified power banks from domestic flights underscores this broadening effort. Each event reinforces a stark lesson: when safety rules falter, even one small cell can jeopardise lives and aircraft.
The authorities are responding with tighter monitoring, collaborative audits, and new compliance programmes. Airlines now track battery shipments through digital systems connecting ground operations and regulatory databases. The goal is to eliminate grey zones where unsafe or undeclared cargo might slip through.
Emerging technologies promise additional layers of security. Internet of Things (IoT) sensors embedded in cargo containers allow real-time temperature and smoke monitoring. These systems transmit data to operations centres, giving airlines early warnings of irregular heat buildup.
Artificial intelligence models now scan booking data for patterns that suggest undeclared hazardous goods. Meanwhile, aircraft manufacturers are testing enhanced cargo compartment fire suppression systems specifically engineered for lithium battery combustion characteristics.
Airlines and handlers continue to update training content and inspection routines as part of larger safety programmes. IoT tracking, automation, and improved material science are shaping what specialists describe as the next generation of air cargo safety. Regulators are also refining inspection protocols for mixed loads containing both certified and non-certified parts, a frequent reality in e-commerce.
The collective task ahead
The safe transport of lithium batteries hinges on shared responsibility. From shippers who must declare contents accurately to airlines that must inspect and package them correctly, every link in the logistics chain carries part of the load. Training, documentation, and screening remain the cornerstones of prevention. “Collaboration is the key to closing the gaps that cause compliance failures,” Liu said.
Spiga echoed the sentiment, emphasising coordination between “customers, regulators, and carriers to ensure that only compliant batteries move by air.”
Incidents from the past stand as reminders of what is at stake. Financial losses from cargo fires can exceed millions, but the greater cost lies in the potential loss of life and aircraft.
As lithium battery production rises with global electrification, airlines and logistics operators can no longer treat these shipments as routine cargo. The safety of modern flight, increasingly intertwined with the convenience of rechargeable energy, rests on constant vigilance across the entire supply chain.