Innovative battery container 2026: Safe storage for class 9

The transportation of lithium batteries in accordance with dangerous goods class 9 is strictly regulated – and choosing the right packaging can make the difference between approval and a fine. Anyone shipping battery storage systems, electric vehicles or industrial energy modules by road, rail, ship or air today is subject to a set of regulations consisting of ADR, RID, ADN, IMDG and IATA/ICAO. Each of these regulations places specific requirements on safe lithium-ion transport containers – in terms of test certificates, labeling and material properties.

wi-sales GmbH develops and produces ThorPak battery systems that meet precisely these requirements. This page shows which system is suitable for which application – with a comparison table, certification overview and direct contact options.

Dangerous goods class 9 includes substances and articles that pose a hazard during transportation but do not fall under classes 1-8. Lithium-ion batteries (UN 3480) and lithium-metal batteries (UN 3090) are the best-known representatives of this class. Unlike classes with classic packing groups I-III, the packing instructions for lithium batteries are based on the number of watt hours (Wh) and the cell type.

ADR Special Provision 188 defines the limits for simplified transportation: lithium-ion single cells up to 20 Wh, batteries up to 100 Wh. In addition, the full packing instruction P903 or LP903-LP905 applies. For the safe transport of lithium-ion batteries, choosing the right container is not an optional optimization, but a regulatory requirement.

Material requirements for battery containers

The packaging instructions LP903-LP905 define specific material requirements. Containers must be made of non-flammable, chemical-resistant materials and be able to withstand heat and pressure in the event of a thermal runaway. HDPE (high-density polyethylene) has established itself as the standard material – it is impact-resistant, UV-resistant and can be replaced in the event of damage without having to abandon the container structure.

In addition, some shipping routes (especially air freight according to IATA) require a secondary containment level. This is where the SwagBag inner packaging comes into play: a specially developed inner bag that significantly limits gas development and flame spread in the event of thermal incidents. The combination of ThorPak outer container and SwagBag is currently the most common setup for regulatory safe battery transportation.

ThorPak battery systems in comparison

wi-sales offers three certified battery container systems for different applications. All three variants comply with the packaging instructions LP903, LP904 and LP905 of the ADR and are approved for the relevant transport routes.

All three systems are designed as reusable containers and significantly reduce the packaging costs per cycle compared to disposable carton solutions. For air transport, wi-sales recommends the combination with the SwagBag inner packaging, which acts as a secondary containment layer in accordance with IATA Dangerous Goods Regulations.

Certifications and test certificates

Every ThorPak battery container bears the UN approval mark in accordance with Chapter 6.1 or 6.6 ADR. This mark proves that the container has passed the prescribed tests: stacking test, drop test, sealing test and – in the case of large packaging – lifting test. Separate test reports are available for international sea freight (IMDG) and air freight (IATA/ICAO).

Dangerous goods officers can receive the following documents from wi-sales on request: UN type approval certificate, manufacturer’s confirmation of conformity, current test report from the commissioned testing institute. All documents are available in German and, if required, in English.

Cost-benefit analysis of different container types

The classic alternative to certified reusable containers is disposable cardboard packaging with UN approval. It is cheaper to purchase, but causes considerable follow-up costs with regular shipping volumes: cardboard packaging, inner padding, disposal, handling costs. With a shipping volume of 50 units or more per month, ThorPak battery systems usually pay for themselves within 6-12 months.

There is also the compliance advantage: a standardized reusable container reduces the risk of packaging errors, which can lead to fines or freight rejection during routine inspections. For an individual cost calculation based on your shipping quantity, please contact the wi-sales sales team.

Ordering and customization

ThorPak battery systems are available from stock. Special dimensions and customer-specific labeling (e.g. UN marking with company logo) are available on request. The minimum order quantity for custom-made products is typically 50 units – depending on container size and configuration.

Send inquiries via the contact form or directly to the sales team. For larger projects – e.g. the introduction of a standardized shipping system for several locations – wi-sales recommends a personal consultation including a live demo.