Storage of lithium-ion batteries: the logistics industry continues to ignore the real risks. Expert warns!
Lithium-ion batteries are now present in virtually every market segment, from phones, laptops and power banks, through power tools, to scooters and electric bicycles. At the same time, they are increasingly finding their way into the warehouses of 3PL operators and distribution centres. The problem is that the logistics industry still treats them as ordinary goods.
According to Wojciech Wiśniewski, Business Development Director and Dangerous Goods Safety Advisor at ADECON, this is a serious mistake that can have disastrous operational and financial consequences.
‘The biggest misconception is the assumption that lithium-ion batteries are neutral goods. They are not. They are goods that can start a fire on their own, without any external factor,’ emphasises the expert.
A risk that other goods do not have
Most warehouse products require an ignition source: a spark, flame, friction or high temperature. In the case of Li-Ion cells, an internal defect or mechanical damage is sufficient. This phenomenon is referred to as thermal runaway – a rapid transition of the reaction to an uncontrolled phase.
‘This is something that ordinary goods do not do. A newspaper, pallet or cardboard box does not ignite on its own. A lithium-ion battery - absolutely.’
Once ignition occurs, the situation escalates quickly. A battery fire is difficult to extinguish because the energy is generated inside the cell, not on the surface. In addition, hot cells can literally ‘shoot out’ of devices, igniting the surrounding area.
‘You can't put it out with a fire extinguisher. You have to wait out the fire, control it and isolate it. And in a warehouse without separation and systems, that means it will spread to other pallets.’
The industry continues to pretend that ‘these are not hazardous materials’
According to the expert, the problem has two sources:
1. Lack of awareness of what is actually being stored
Warehouse operators are increasingly accepting goods containing batteries: scooters, power tools, household appliances, industrial equipment and electric bicycles - but often they do not even know that they are handling Li-Ion.
Importantly, Li-Ion batteries ‘enter warehouses through the back door’ in the form of entire devices. These are not just raw cells or packs, but primarily everyday electronics, including:
- phones
- laptops
- power banks
- power tools
- electric bicycles and scooters
- service modules
- industrial parts kits
In some cases, this lack of awareness is not due to ignorance, but to the very nature of the market.
2. Incorrect declaration of goods
Here, another growing market pathology emerges:
‘I am seeing batteries declared as “spare parts” more and more often. This is a terrible idea. Firstly, because it does not reflect the risk class, and secondly, because it misleads the operator. The warehouse is not aware of what it is storing.’
The consequences? Not only fire, but also insurance
Operators hope that in the event of an incident, ‘the insurer will pay’. However, with Li-Ion, this assumption is often wrong.
‘If the warehouse does not meet the technical requirements, the insurer may withdraw from the payment. The operator is left alone with claims and a destroyed warehouse. This is not a theoretical risk - it already happens.’
Five elements that a Li-Ion warehouse should have
According to Wiśniewski, the following should be standard:
1. Active systems – anomaly detection
Thermal imaging, sensors, analytics. ‘The idea is to detect the problem before it turns into a fire.’
2. Passive systems – limiting the spread
“It’s not about extinguishing. It’s about buying time.”
Separations, sprinklers, zoning, chambers.
3. Realistic insurance requirements
The policy must take into account the risk class and facility certifications.
4. Emergency procedures + trained personnel
Not just a binder, but rehearsed scenarios.
5. Continuous operational supervision
This is not a warehouse that can be left ‘unattended overnight’.
Is the market ready?
The short answer is no. There are very few facilities in Poland that meet the above criteria - and this must be made clear.
‘They are more expensive to build and more expensive to operate. But this is the only way if we want to be serious. The problem is that the market still prefers to store goods any old way – as long as it's cheap.’
What should companies that store Li-Ion in standard warehouses do?
The expert lists three options:
(1) raise risk awareness,
(2) modernise the facility, or
(3) move the goods to a dedicated warehouse.
The last option is ‘risk acceptance’, but then you have to take into account that: ‘The insurer will say: “we're not paying”.’
And the Li-Ion market is still growing
At a pace that does not give the industry any comfort.
‘In this industry, it's not a question of if an incident will happen, but when. Whoever understands this first will have an advantage and less exposure to risk.’