Encasing industrial batteries and protecting them in transit involves a specific range of demands which cannot be met by most traditional packaging solutions. The casing serves as the first line of defence against physical damage, chemical leaks, and environmental factors that could compromise the integrity of the battery.
In the UK, the production and use of battery casings are governed by specific regulations designed to ensure the safety of users and to minimise environmental impact.
What are the UK Regulations for battery casing, packaging and transportation?
The UK’s regulatory framework governs the manufacturing, testing, and use of battery casings to ensure that they are robust enough to protect the battery and safe for use in various applications, from consumer electronics to electric vehicles. UK regulations cover all types of batteries, including lithium-ion, lead-acid, and nickel-metal hydride, among others. Most of the key regulations are rooted in international standards, which the UK has adopted and adapted:
- The Battery Directive 2006/66/EC is an EU directive which remains influential in UK law, governing the handling, transportation, and recycling of batteries. It emphasises the need for battery casings to be durable, safe, and environmentally friendly, particularly with regards to recycling
- The Waste Electrical and Electronic Equipment (WEEE) Regulations require that battery casings are designed with end-of-life disposal in mind. This means using materials that are recyclable and do not pose a hazard during disposal or recycling processes.
- The Carriage of Dangerous Goods and Use of Transportable Pressure Equipment Regulations (CDG) 2009 states that for batteries classified as dangerous goods, the casing/packaging must be able to withstand transportation hazards without compromising the safety of the battery or its surroundings.
- The International Air Transport Association (IATA) Dangerous Goods Regulations set out specific packaging requirements for batteries. The UK adheres to these regulations which are particularly strict for lithium batteries due to their potential risk of fire.
- The European Waste Framework Directive is primarily concerned with waste management and applies to batteries that are considered waste, requiring them to be transported in a way that avoids leaks and environmental contamination.
To comply with these regulations and standards, battery casing and packaging must protect users from exposure to potentially hazardous chemicals and prevent short circuits, fires, and explosions. Casing must withstand physical impacts, temperature variations, and chemical exposure over the battery’s life. As well as being recyclable, casing materials should be free from toxic substances, reducing environmental harm at the end of the battery’s life. The packaging must also be strong enough to withstand the rigors of transport and resistant to environmental conditions such as moisture and temperature fluctuations that might be encountered during long journeys.
Certain types of batteries, particularly lithium-ion, must pass the UN Manual of Tests and Criteria Part III, Subsection 38.3. This involves rigorous testing for factors such as altitude simulation, thermal conditions, vibration, shock, external short circuit, impact, and overcharge. Only batteries that pass these tests can be legally transported. Packaging must therefore be designed to ensure that the batteries remain in the same condition as when they passed these tests, without any deterioration during transit.
Packages containing batteries must be clearly labelled with appropriate hazard symbols and include handling instructions, such as warnings against exposure to fire or water, to ensure that the packages are handled with care during all stages of transportation.
Best practice in packaging design for battery transportation
The design and manufacture of packaging for batteries should follow the following guidelines to meet regulatory standards.
- Batteries and cells must be packed in a strong, rigid and non-conductive outer packaging.
- Inner packaging should also be made of robust and non-conductive material.
- Exposed terminals or connectors must be protected with non-conductive caps or tape.
- Packaging containing multiple batteries must separate them with trays, sleeves or dividers made from non-conductive materials to prevent short circuits and damage to terminals.
- Packaging should be custom-designed to prevent movement during transit, which could cause terminal caps to loosen or batteries to activate accidentally.
- Fragile batteries like lithium-ion cells should have adequate cushioning to protect them from physical damage during transportation.
- Packaging should be manufactured from materials that help to prevent leaks.
Why corrugated polypropylene is an ideal material for battery casing and packaging
Corrugated polypropylene (also known in the industry as correx) has emerged as an ideal material for battery packaging and casing, providing reliable protection which is beyond the capability of other materials such as cardboard. Polypropylene has a unique range of attributes that align well with UK regulatory requirements:
Impact Resistance
Corrugated polypropylene is highly resistant to impact, making it an excellent material for battery casings that need to protect sensitive internal components from physical damage.
Chemical and water resistance
Corrugated polypropylene is resistant to moisture and a wide range of chemicals, including acids, bases, and solvents, which is crucial for battery casings that may come into contact with corrosive substances.
Weight reduction
Corrugated polypropylene is much lighter than traditional materials like metal or hard plastics, which is particularly beneficial for applications where weight is a critical factor, such as in electric vehicles and portable electronics. Reducing weight also reduces transportation costs.
Design versatility
Corrugated polypropylene can be easily shaped into various forms, allowing manufacturers to design casings that meet specific requirements for different battery types. The material can be moulded in a way that eliminates or minimises movement within the package.
Heat resistance
Corrugated polypropylene has good thermal insulation properties, which helps in protecting the battery from temperature extremes that could affect its performance or safety.
Electrical insulation
Corrugated polypropylene is an excellent electrical insulator, reducing the risk of short circuits and enhancing the overall safety of the battery.
Recyclability
Corrugated polypropylene is fully recyclable, aligning with the WEEE and Battery Directive requirements for end-of-life disposal. This reduces the environmental impact of battery disposal and contributes to a circular economy.
Lower production costs
The manufacturing process for corrugated polypropylene is less complex and less expensive than for many alternative materials. This cost-effectiveness makes it an attractive option for large-scale solutions.
Protection
By providing excellent protection and insulation, corrugated polypropylene casings can help extend the life of the battery, reducing the frequency of replacements and the associated costs.
Minimising leakage
corrugated polypropylene’s resistance to chemicals makes it excellent for containing leakage. The ‘fluted’ construction, which forms tubes of air on the inside of each sheet, is also ideally suited to channelling any run-off and keeping it within the casing/packaging.
Corrugated polypropylene has become a go-to material for battery casings and packaging, meeting and often exceeding regulatory requirements. Its combination of durability, lightweight, chemical resistance, thermal insulation, recyclability, and cost-effectiveness makes it a preferred choice for many battery manufacturers and suppliers. As the demand for batteries continues to grow, particularly in the electric vehicle and renewable energy sectors, the use of corrugated polypropylene in battery casings is likely to become even more widespread, contributing to safer, more sustainable solutions.
For more advice on bespoke packaging and casing solutions for batteries, please contact Twinplast’s Technical Sales Team on 01582 361720 or sales@twinplast.co.uk