Ship Lithium-Ion Batteries

I've scoured the forums and have exhausted my search of up to date details on how to ship Li-Ion batteries and cells. After searching around the internet, I found that the DOT requires all lithium and lithium ion batteries to be shipped via ground transportation unless it is installed in the device it operates. As per USPS:

Originally Posted by USPS Hazardous Materials Appendix C: Lithium Batteries

Secondary (rechargeable) properly installed in the equipment they are intended to operate:
-Mailable via air transportation or surface transportation domestically or internationally or to and from APO, FPO, and DPO locations.
-No markings required provided the quantities are within the limits of 349.22 (for domestic items), or 622.5 (for international, and APO, FPO, and DPO items).

Secondary (rechargeable) packed with the equipment they are intended to operate:
-Mailable via air and surface transportation domestically. Prohibited internationally or to and from APO, FPO, and DPO locations.
-The outside of the package must be marked on the address side “Package Contains Lithium-ion Batteries (no lithium metal).”

Secondary (rechargeable) not packed with or installed in equipment (individual batteries):
-Mailable domestic via surface transportation only. Prohibited internationally or to and from APO, FPO, and DPO locations.
-The outside of the package must be marked on the address side “Package Contains Lithium-ion Batteries (no lithium metal).”

It appears taping the terminals and throwing it in a flat rate box isn't good enough anymore. Maybe not such a big deal on the mainland, mailing things from Hawaii almost always requires air transportation. FedEx and UPS Ground services even use air freight leaving the only option for us USPS Parcel Post or Media Mail. Does anyone have any thoughts? Since we learned this "new" requirement from the DOT, we've been stockpiling our Li-Ion batteries until we found a solution (Parcel Post isn't worth it against the prices we are getting for the batteries).

I believe you can disclose it is li ion batteries...will cost more to ship as dangerous, but I believe they handle it differently....I am not 100% sure however. The other option would be to stockpile until you get enough for at least a gaylord or become the buyer for the area and ship them out in a shipping container. You would at least be able to get bulk pricing, but you will have to do the research on the best place to sell that much to.

We pretty much work with laptop batteries and the CMOS batteries in motherboards. If I am reading the pricing correct, ewasted required us to remove the battery cells from motherboards. And according to the USPS, shipping the batteries with the equipment they operate is okay via air. So putting them in the same box as the motherboards (but not installed) is alright? I am really so confused.

they really are looking more at the ones with terminals...if you cross li ion batt terminals with another one they will heart up and eventually catch fire (they get REALLY hot). You should be able to keep the motherboard ones separated (I do not think he buys those however) I think he buys laptop and maybe cell phones li ion only. the others are specialty li ion batteries....just like power tool batt packs are a specialty as well. Check with him to verify.

You COULD get sneaky and use a vacuum sealer...put all the batteries spaced out and seal around them...it should create a pocket for each...you can cut into strips of batteries and stack them. I was thinking that would be be a great way to not have to tape terminals if you did a bunch of batteries. Quick and efficient.

Again, it might be a service you could provide for others in the islands and ship out in bulk...something to think about as obviously it is a problem.

I actually called the post office with this very question, both the local and 800 number. It was really difficult to get an answer as it seems no one ever asked it before. Apparently if the battery is installed in the device, it can go air but needs to be declared. However, I was told that batteries alone had to go ground, and also declared. Anyway, this is what I was told...

From my understanding, the issue with lithium ion batteries is that the crushing alone isn't enough to cause a fire. The problem is that incorrectly manufactured or damaged lithium cells can actually cause the battery to burst at high altitudes (a cargo hold pressurized to 7000 ft. is still enough to burst a defective lithium battery).

In Hawaii, the only ways to transport via ground are USPS Parcel Post or sea freight. And even then, you still need this label on your packaging:

I'll stop by the post office either tomorrow or Friday and try to get a clear answer from the clerk (they've been really helpful with all the other questions I've had). And if there isn't anyway to send them economically, perhaps I've discovered a new revenue stream for myself!

Yes that is Ewasted aka Mario. I suggest you contact him through his web site. Be prepared to give the weight and what dimensions to give the best chance for him to give you the best deal on shipping.

Also note that the batteries need to have the contacts taped before shipping. 73 Mike