Introduction
In 2025, the global power bank market exceeds $15.56 billion, driven by high-capacity 20,000–50,000mAh models and Qi2.2 wireless charging. But with growth comes risk: improper handling and shipping of lithium-ion power banks can lead to fires, explosions, and massive regulatory fines.trust-freight.com
The truth: every commercially sold power bank is classified as UN3480 – Class 9 Dangerous Goods (DG). Yet, with proper compliance, shipping is entirely manageable.ul.com
This guide is tailored for B2B brands, OEM/ODM manufacturers, and e-commerce sellers, covering DG rules in China, international air and sea shipping, sample vs mass shipments, packaging, labeling, and documentation.
1. Why All Power Banks Are Dangerous Goods (UN3480)
Key fact:
- Standalone lithium-ion batteries (power banks) = UN3480
- Contained-in-equipment or packed-with-equipment batteries are UN3481, but most power banks are standalone → UN3480.
Exceptions:
- Tiny cells ≤ 2.7Wh (practically non-existent)
- Batteries permanently inside equipment, non-removable (rare for power banks)
⚠️ All other power banks, whether 10,000mAh or 50,000mAh, fall under Class 9 DG.vibms.com
2. Dangerous Goods & Lithium Battery UN Classifications
| UN Number | Description | Typical Use Case | Passenger Aircraft | Cargo Aircraft | Sea/Road |
|---|---|---|---|---|---|
| UN3480 | Lithium-ion batteries (standalone) | Power banks | Forbidden (except CAO) | Allowed ≤30% SoC | Allowed |
| UN3481 | Lithium-ion packed with/contained in equipment | Phones + power banks | Allowed (≤5 kg) | Allowed (≤35 kg) | Allowed |
| UN3090 | Lithium metal batteries (standalone) | Rare, non-rechargeable | Forbidden | Restricted | Allowed |
| UN3091 | Lithium metal packed/contained | Coin cells / devices | Limited | Limited | Allowed |
All power banks = UN3480 → forbidden on passenger aircraft unless approval is obtained.ul.com
UN3480 vs UN3481 Flowchart Alt: Flowchart: “UN3480 vs UN3481 – How to classify your power bank” (Ready-to-upload: Download from IATA guidance or create via Canva with steps: Is it standalone? → Yes = UN3480; No = UN3481)
UN3480 Lithium Battery Mark Alt: UN3480 lithium battery mark (Ready-to-upload: Standard UN mark graphic with dimensions 100x70mm, showing the UN3480 symbol, handling label, and phone number)
3. Watt-Hour (Wh) Calculation & Aviation Limits
Formula: Wh=(mAh1000)×Voltage (V) \text{Wh} = \left( \frac{\text{mAh}}{1000} \right) \times \text{Voltage (V)} Wh=(1000mAh)×Voltage (V)
| Power Bank Capacity | Voltage | Wh | Aviation Section |
|---|---|---|---|
| 10,000mAh | 3.7V | 37Wh | Section II – allowed on cargo aircraft |
| 20,000mAh | 3.7V | 74Wh | Section II – allowed |
| 30,000mAh | 3.7V | 111Wh | Section II – edge, special courier approval |
| 50,000mAh | 3.7V | 185Wh | Section IA – full DG, high cost, cargo only |
Airline Passenger Rules:
- ≤100Wh: can carry on airplane (usually 2 units max)
- 100–160Wh: airline approval needed
- ≥160Wh: forbidden on passenger aircraft
4. China DG Rules – Single Cell & Battery Pack
- Single cell >20Wh → DG regulated, must use UN certified packaging
- Battery pack >100Wh → DG regulated, must use UN certified packaging
- DG containers (Class 9, UN label) required for large shipments exceeding these thresholds
- Note: Sea freight often requires UN packaging + DG labeling, air cargo strictly enforces SoC ≤30%
- New in 2025: Mandatory UN38.3 test report submission at ports like Ningbo for DG lithium batteries. Export controls on high-energy density batteries (≥300 Wh/kg).en.gdestl.com
Required Certificates for China Exports (2025): To comply with Chinese customs and international transport, the following documents are essential for UN3480 power banks:
- UN38.3 Test Report & Summary: Certifies the battery has passed UN safety tests (T1-T8 simulations for transport). Mandatory for all lithium batteries; must be from an accredited lab (e.g., UL, TÜV). Valid for 3–5 years.jjrlab.com
- MSDS/SDS (Material Safety Data Sheet): Details chemical composition, hazards, and handling. Required by carriers like DHL/FedEx; not a transport doc per IATA but often mandatory for clearance.phmsa.dot.gov
- Air/Sea Transport Appraisal Report (空海运鉴定报告): A China-specific DG identification report issued by authorized labs (e.g., CIRS, CTI). Confirms the battery’s transport safety for air (IATA) and sea (IMDG). Essential for customs export declaration; includes SoC verification and packaging assessment.iata.org
These must accompany shipments; non-compliance leads to port rejection.
5. Shipping Methods Comparison (2025 Updated)
| Shipping Method | Allowed? | Max/Package | Cost | Transit Time | Notes |
|---|---|---|---|---|---|
| DHL / FedEx / UPS Express | Yes, ≤100Wh Section II | 1–4 pcs | $80–$180/kg | 3–6 days | Best for samples, prototypes |
| Air Cargo (CAO) | Yes | ≤35 kg net | $6–$12/kg | 7–12 days | Bulk shipments |
| Sea Freight LCL | Yes | No practical limit | $800–$1500/cbm | 25–40 days | Cheapest for mass production |
| Sea Freight FCL | Yes | Full container | $3000–$5000/20ft | 25–40 days | Very large volume |
| Road/Truck (EU/US) | Yes | No limit | Cheapest | 5–14 days | Regional |
Note: Max Wh limits apply per battery (≤100Wh for Section II); chart focuses on cost/time. Ready-to-upload: Embed this Chart.js config via your CMS plugin (e.g., WordPress Chart.js block).
6. Courier Policies 2025
DHL
- Accepts ≤100Wh Section II only
- Max SoC 30% strictly enforced
- Requires MSDS, DG declaration
- Note: DHL eCommerce does not accept power banks.intertek.com
FedEx
- Section II UN3480 on CAO only
- 30% SoC
- Express >100Wh → rejected
- Proper packaging and UN38.3 required.maskuralogistics.com
UPS
- Most restrictive for air
- Section IA/IB only for high Wh
- Prefers ground or sea for high-capacity power banks
- Damaged batteries ground-only.
Tip: For samples ≤100Wh, DHL Express is fastest and simplest. For mass shipments, Air Cargo or Sea LCL is cost-effective.
7. Samples vs Mass Production Shipments
| Aspect | Samples/Prototypes | Mass Production |
|---|---|---|
| Quantity | 1–50 pcs | 500+ pcs |
| Section | II | IB / IA possible |
| SoC | ≤30% | ≤30% (air) / unrestricted (sea) |
| Packaging | Simplified | UN certified boxes + DG labeling |
| Cost/unit | $15–50 | $1–4 |
| Best Method | DHL Express | Sea LCL / CAO Air |
8. Step-by-Step Guide: Ship Power Banks Compliantly
- Calculate Wh of power bank
- Confirm UN38.3 test report + summaryjjrlab.com
- Charge to ≤30% for airvibms.com
- Select Section (II easiest for samples)
- Use inner packaging (plastic bag, bubble wrap, terminals taped)
- Use strong outer carton (drop test compliant)
- Apply Lithium Battery Mark + Class 9 label + CAO label
- Prepare Air Waybill + MSDS + DG declaration (include UN38.3 summary and Air/Sea Transport Appraisal Report for China exports)
- Book approved carrier (DHL battery channel, Air Cargo, Sea LCL)
- Track shipment & maintain documentation
Section II Packaging Alt: Section II bubble-wrapped boxes (Ready-to-upload: Photo of individually wrapped power banks in carton)
Class 9 Label Alt: Class 9 label (Ready-to-upload: Official IATA label template PNG)
UN3480 Mark Alt: UN3480 lithium battery mark (Ready-to-upload: Standard UN mark graphic with dimensions 100x70mm)
9. Common Mistakes to Avoid
- Shipping at full charge
- Using wrong UN number (UN3481 vs UN3480)
- Missing UN38.3 report
- Forgetting CAO / DG label
- Misjudging SoC limits for air
10. FAQs
Q: Can I ship a 30,000mAh power bank by DHL? A: Yes, ≤111Wh, Section II, max 2 pcs/package
Q: Are all power banks UN3480? A: Yes, all standalone mobile power banks
Q: Can I carry power banks on a passenger plane? A: ≤100Wh is allowed, >100Wh requires airline approval, ≥160Wh forbidden
Q: Does China require DG packaging for >100Wh battery packs? A: Yes, UN certified boxes + DG label required
Q: Can sea shipments bypass 30% SoC rule? A: Yes, IMDG allows full SoC for sea cargo
Q: Samples vs mass shipment differences? A: Samples → Section II, express allowed; Mass → UN packaging, sea or cargo air preferred
Conclusion
All mobile power banks are UN3480 Class 9 Dangerous Goods. Compliance is non-negotiable for:
- China customs (cell >20Wh, pack >100Wh → DG packaging)
- Air transport (≤100Wh passenger limit, 30% SoC for cargo)
- Courier acceptance rules
With proper classification, SoC, packaging, labeling, and documentation, shipping power banks is safe and routine.
ReachInno helps OEMs/ODM brands ship samples or mass power banks worldwide fully compliant with UN38.3, DG rules, and 2025 carrier requirements.
