Live electrical products can be shipped internationally by air, but due to potential electrical safety risks (such as short circuits, overheating, and fire), the International Air Transport Association (IATA) and national aviation authorities and customs authorities have strict classification, certification, and transportation regulations. Live electrical products that do not meet these requirements will be rejected by airlines and may even face penalties.
- Air Transport Classification of Live Electrical Products (Core Prerequisite)
First, it is necessary to identify the specific category of live electrical products. The transportation requirements for each category vary significantly, which is the basis for determining whether and how they can be shipped by air. According to the IATA Dangerous Goods Regulations (DGR), common classifications are as follows:
Non-restricted live electrical products (normal live electrical products)
These products contain only internal or removable batteries, but the batteries are stable, have low energy levels, and will not pose safety risks due to vibration, compression, or other factors during normal transportation.
Typical examples include standard Bluetooth headsets, mobile phones with built-in lithium batteries (not bare metal), power banks (capacity ≤100Wh), and standard electric toys (non-hazardous components).
These products can generally be shipped as “general cargo” or “restricted cargo” and do not require strict dangerous goods declarations, but must meet basic packaging and information requirements.
Restricted/Dangerous Goods: Electrically Conductive Products
These products are classified as dangerous goods (usually Class 9 miscellaneous dangerous goods) due to their high battery capacity, potential safety hazards, or hazardous components.
Typical examples include high-capacity power banks (>100Wh and ≤160Wh), self-balancing scooters, electric wheelchairs, medical devices containing lithium batteries, and electrically conductive chemical testing equipment.
These products must strictly follow dangerous goods transportation procedures, including dangerous goods declaration, use of compliant packaging, and affixing dangerous goods labels. Some even require special approval from airlines.
Live Electrical Products Prohibited from Air Transport
These products pose an extremely high safety risk and are explicitly prohibited from air transport by IATA and various national aviation authorities.
Typical examples include uninsulated bare batteries, damaged or leaking batteries, lithium batteries with a capacity greater than 160Wh, and live electrical equipment containing flammable or explosive components (such as certain military live electrical devices).
II. Core Certification Requirements for Air Transport of Live Electrical Products
Different countries/regions have different import certification requirements for live electrical products. Lack of the required certification can result in customs clearance delays, detention, or even destruction of goods at destination. Common certifications are as follows:
Global/Basic Certifications
UN38.3 certification: This is the basic mandatory certification for all products containing lithium batteries shipped by air. Developed by the United Nations Committee of Experts on the Transport of Dangerous Goods, it tests the safety of lithium batteries by simulating transportation environments such as high altitude, low pressure, temperature cycling, vibration, shock, and short circuits, verifying that they will not catch fire, explode, or leak during transportation. Any powered product (even a standard Bluetooth headset) containing a lithium battery will require a UN38.3 test report from the airline.
Certifications for Export to Specific Regions
EU: CE Certification (LVD Directive + EMC Directive)
Powered products entering the EU market must obtain CE certification. The LVD Directive (Low Voltage Directive) governs electrical safety, while the EMC Directive (Electromagnetic Compatibility Directive) governs electromagnetic emissions and interference immunity. A test report demonstrating compliance with the directives is required.
US: FCC Certification
Powered products entering the US must obtain FCC certification to demonstrate that their electromagnetic compatibility (EMC) performance complies with Federal Communications Commission (FCC) standards to prevent interference with US radio communications.
Canada: IC Certification
Similar to the US FCC certification, this is a mandatory EMC certification for powered products entering the Canadian market.
Japan: PSE Certification
Japan’s mandatory safety certification for electrical products is divided into “Specified Electrical Products” (requiring the diamond-shaped PSE mark, such as large-capacity batteries) and “Non-Specified Electrical Products” (requiring the circular PSE mark, such as low-power chargers).
Other regions, such as Australia’s C-Tick certification, South Korea’s KC certification, and the UKCA certification after Brexit, all require advance processing according to the regulations of the destination country.
III. Specific Transportation Requirements for Air Freight of Electrical Products
In addition to certification, packaging, labeling, and declaration procedures for electrical products must strictly comply with IATA Directive Regulations (DGR) and airline regulations. Core requirements include:
Packaging Requirements: Insulation, Isolation, and Damage Prevention
Batteries must be packaged individually or with the equipment to ensure that the electrodes (positive and negative) do not come into contact with other conductive materials, causing a short circuit. Typically, batteries are wrapped with insulating material (such as bubble wrap or insulating bags), or insulating spacers are placed in the battery box.
The packaging must be sufficiently resistant to pressure and shock to prevent damage to the battery during transportation. For example, power banks must be packaged in a rigid cardboard box filled with cushioning material.
For devices with removable batteries, it is recommended that the battery be installed inside the device for transportation. If transporting batteries separately, each battery must be packaged separately, and the number of batteries in a package must comply with airline restrictions.
Labeling and Labeling Requirements: Clear Information and Clear Warnings
The outer packaging must be affixed with a “Lithium Battery Handling Label” (for hazardous materials containing electrical components, a Class 9 dangerous goods label with the UN number, such as UN3480 for lithium-ion batteries, must be affixed).
The packaging must clearly indicate the shipper, consignee, and contact information, as well as a warning such as “Lithium Battery Included.”
If the battery capacity is greater than 100Wh, the packaging must be labeled with the battery’s rated energy (e.g., “120Wh”) and battery type (e.g., “Lithium Ion Battery”).
Declaration Requirements: Truthful Declaration with Complete Documentation
For non-restricted live electrical products, the following information must be accurately stated on documents such as the airway bill and commercial invoice: “Live Electrical Products,” “Contains Lithium Batteries,” and the battery type, quantity, and rated energy. Concealing the item as “ordinary cargo” is not permitted (failure to do so may result in significant fines and full liability for any safety issues with the cargo).
For restricted/dangerous live electrical products, a Dangerous Goods Declaration Form (DGD) must be submitted and completed by a qualified freight forwarder or shipper. Documents such as a UN38.3 test report and a dangerous goods classification identification report must also be provided. The Dangerous Goods Transport Approval from the airline must be obtained.
Quantity and Weight Limits: Comply with airline regulations.
The number of live electrical products and the total weight of batteries in a single shipment must comply with airline restrictions. For example, most airlines limit the number of power banks shipped by individuals to 2-4 per shipment, with a capacity of no more than 160Wh. For bulk shipments, space and transportation limits must be confirmed with the airline in advance.
Dangerous goods (electrical) products must typically be transported in designated aircraft cargo holds (such as segregated holds) and should not be transported in the same hold as flammable, explosive, or corrosive cargo.
Important Notice
Different airlines may have different policies regarding the transportation of electrical products (for example, some airlines may not accept high-capacity lithium batteries). Before shipping, please confirm the latest requirements with your freight forwarder or directly with the airline.
We recommend entrusting professional freight forwarders with “dangerous goods transport qualifications” to transport electrical products by air. These forwarders are familiar with certification processes, packaging specifications, and declaration requirements, effectively avoiding cargo rejections or customs clearance issues due to improper handling.
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