Safety at Speed: How Maersk Delivered High-Risk EV Batteries in 72 Hours, Fully Compliant and Incident-Free

Safety at Speed: How Maersk Delivered High-Risk EV Batteries in 72 Hours, Fully Compliant and Incident-Free

Maersk Air Freight enabled a global EV leader to meet critical production deadlines through precision dangerous goods logistics.

The Customer

A leading electric vehicle (EV) manufacturer required urgent air freight for lithium-ion batteries, classified as UN3480, Class 9 Dangerous Goods, from China to Latin America. These high-energy batteries are crucial to the customer's EV assembly operations, and shipping them by air presents significant safety and regulatory challenges.

Faced with a narrow production window and stringent transport protocols, the customer needed a logistics partner with the ability to act fast, navigate complex international regulations, and ensure 100% safety along the way. That's where Maersk Air Freight stepped in.

The Challenge

The transportation of lithium-ion batteries presents unique complexities that challenge even experienced logistics providers. These UN3480 Class 9 dangerous goods carry inherent risks, including thermal runaway, potential short circuits, and fire hazards that require specialized handling protocols.

The customer faced three critical obstacles. First, navigating the intricate web of IATA dangerous goods regulations while ensuring full compliance across multiple international jurisdictions.

Second, managing the safety risks associated with lithium battery transport, where even minor documentation errors could result in shipment rejection or safety incidents.

Third, meeting urgent delivery deadlines is essential for maintaining production line continuity; any delays would cascade through their entire manufacturing schedule, potentially costing millions in lost production.

Standard air freight solutions were inadequate for this high-stakes scenario, requiring a logistics partner with certified expertise in handling dangerous goods and the operational flexibility to deliver within a 72-hour window.

The Solution

Leveraging its position as an IATA-certified dangerous goods operator, Maersk Air Freight implemented a comprehensive solution tailored to the customer's specific requirements:

• Own Controlled Flight Network: Maersk utilized its controlled flight network, which streamlined transportation touchpoints and eliminated the complexity of multiple carrier handoffs. This controlled network proved particularly valuable when Maersk expanded its China-US route to include Latin America in May, directly aligning with the customer's delivery destinations.
• Pre-Shipment Compliance: Maersk's dangerous goods specialists ensured all batteries were charged to precisely ≤ 30% State of Charge (SoC), the maximum safe level for air transport, meeting strict IATA regulations for lithium battery transportation.
• Secure Packaging & Labeling: The team implemented rigorous packaging protocols, applying Class 9 hazard labels, CAO (Cargo Aircraft Only) markings, and specialized Lithium Battery Handling stickers to guarantee full regulatory compliance across all international jurisdictions.
• Temperature-Controlled Logistics: Maersk's specialists continuously monitored storage and transit temperatures throughout the journey, preventing thermal exposure that could trigger hazardous battery reactions and ensuring product integrity.
• Expert Documentation Management: Maersk's IATA-certified specialists handled all dangerous goods documentation, eliminating the risk of regulatory rejections and ensuring seamless customs clearance at each transit point.

The Result

Within just 72 hours, Maersk Air Freight delivered the Class 9 lithium-ion battery shipment from China to Latin America on time, fully compliant, and with zero incidents, rejections, and delays throughout the entire transport process.

The cargo moved seamlessly through our controlled flight network, with all safety protocols, documentation, and temperature conditions met across every leg of the journey.

This execution not only ensured uninterrupted EV production for the customer but also eliminated risk points such as customs rejection, delays, or mishandling during transfer.

What began as a high-risk, high-pressure movement has now evolved into a model for repeatable success. The customer has since expanded their partnership with Maersk to cover additional dangerous good lanes in Asia and North America, confident in our ability to balance regulatory precision with operational speed. For mission-critical cargo, such as lithium batteries, Maersk has proven to be more than just a logistics provider; we're a trusted safeguard for performance, safety, and supply chain continuity.

Take the Next Step with Maersk

In industries where a single delay can ripple across markets, hazardous cargo must be transported with zero error. Maersk Air Freight offers not just capacity, but certified precision, regulatory confidence, and unmatched control.

Discover our Air Freight Solutions or learn how we support logistics for dangerous goods at scale.