How to Properly Apply the USPS Lithium Battery Label on Packages?

How to Properly Apply the USPS Lithium Battery Label on Packages?
To comply with USPS regulations, lithium battery labels must be visibly affixed to the outer packaging, away from seams and edges. Use the standardized UN3481 (lithium-ion) or UN3090 (lithium-metal) label, ensuring it’s at least 4.7×4 inches. Labels must remain unobstructed and legible, with no overlapping tape. Proper placement prevents shipment delays or rejections.

Lufthansa Lithium Policy

What Are the USPS Requirements for Lithium Battery Labels?

USPS mandates specific labels for lithium batteries to indicate hazardous materials. Labels must display the UN number (e.g., UN3481), battery type, and a warning symbol. Domestic shipments require the “Surface Mail Only” notation if applicable. International shipments need additional IATA-compliant markings. Labels must be durable, weather-resistant, and printed in black on white or contrasting backgrounds.

USPS requires labels to meet specific design standards, including font size and symbol proportions. The warning diamond must measure at least 2 inches on each side, with the UN number clearly visible. For pre-printed labels, ensure the ink is smudge-proof and resistant to temperature changes. Shippers should periodically review updates to Publication 52, as label specifications may change. For example, recent updates now require QR codes on labels for high-volume commercial shipments. Failure to comply can result in fines up to $78,376 per violation under federal hazardous materials regulations.

Where Should the Lithium Battery Label Be Placed on a Package?

Place the label on the same surface as the shipping address, ideally adjacent to it. Avoid edges, seams, or corners where damage may occur. For cylindrical packages, position the label on the cylindrical surface. Ensure no other labels, tape, or text obscure the lithium battery warning. Double-check visibility from all handling angles.

Charger for 200Ah LiFePO4

How to Avoid Common Mistakes When Applying Lithium Battery Labels?

Common errors include using undersized labels, incorrect UN numbers, or covering labels with tape. Avoid placing labels near “Fragile” stickers, which might distract handlers. Never reuse old packaging without removing prior lithium markings. Test label adhesion by rubbing lightly; if corners lift, reinforce with clear tape without obscuring text.

What Documentation Is Required Alongside the Lithium Battery Label?

Domestic USPS shipments require a Shipper’s Declaration for Dangerous Goods (Form 8410) for batteries over 2g (lithium-metal) or 100Wh (lithium-ion). International shipments need a detailed commercial invoice declaring battery type, quantity, and watt-hours. Include safety data sheets (SDS) if batteries are damaged or defective.

Are There Packaging Requirements Beyond Labeling for Lithium Batteries?

Batteries must be insulated to prevent short-circuiting. Use individual plastic bags or terminal covers. Secure batteries within rigid, leak-proof packaging. For installed batteries, devices must be switched off and protected from activation. Cushioning materials like foam or bubble wrap are mandatory. USPS prohibits mailing lithium batteries alone to some countries—verify destination restrictions.

Packaging must pass a 1.2-meter drop test without damage to batteries or terminals. Use non-conductive materials like corrugated fiberboard or rigid plastic. For multiple batteries, separate them with dividers to prevent contact. Below is a table summarizing key packaging components:

Material	Purpose	Example
Die-cut foam	Immobilize batteries	Custom-cut polyethylene
Terminal covers	Prevent short circuits	Adhesive polyimide tape
Absorbent material	Contain leaks	Vermiculite packets

How to Verify Compliance with USPS Lithium Battery Regulations?

Use the USPS Postal Explorer tool (Publication 52) to confirm current rules. Cross-check label specs against USPS Designated Service List (DSL) codes. For bulk shipments, consult a hazardous materials advisor. Pre-submit package photos via USPS’s pre-approval program for high-volume shippers. Always retain shipping records for 375 days post-shipment.

Expert Views

“Proper lithium battery labeling isn’t just regulatory—it’s a safety imperative. Misplaced labels risk fires during transit. Always use thermal printers for crisp UN symbols, and conduct staff training quarterly. Remember: USPS scanners read labels top-to-bottom, so orientation matters.” — Logistics Safety Officer, Battery Shipping Alliance

Conclusion

Correctly applying USPS lithium battery labels ensures compliance and safe transit. Prioritize label visibility, accurate documentation, and secure packaging. Regular audits of shipping processes minimize risks. Stay updated on USPS guidelines, as regulations frequently evolve with lithium technology advancements.

FAQs

Q: Can I handwrite lithium battery labels for USPS?

A: No. USPS requires pre-printed, industry-standard labels with specific UN numbers and symbols. Handwritten labels are non-compliant.

Q: Does USPS accept lithium batteries in checked luggage?

A: USPS doesn’t handle luggage. For airmail, lithium batteries in packages must follow IATA’s PI 965/968 rules, differing from FAA luggage guidelines.

Q: How many lithium batteries can I ship via USPS?

A: For lithium-ion: max 8 cells or 2 batteries per package. Lithium-metal: max 2g per battery, 8g total. Exceeding limits requires hazardous materials certification.