From Recall to Road-Ready: What It Takes to Respond Quickly to Lithium Battery Packaging Needs

Featuring insights from Chris Egloff, Vice President of Strategic Opportunities, Americase

Lithium-ion batteries are a mainstay in today’s technology—powering everything from consumer electronics to electric vehicles. While inherently safe, they can carry potential risks when damaged, misused, or defective. In such cases, the need to transport or store these batteries safely becomes ever more important.

Events like product recalls, prototype testing, or shipping damaged batteries often come with tight timelines and high stakes. Companies can’t afford to wait weeks or months to source compliant packaging—and navigating the intersection of safety, compliance, and logistics requires preparation and insight.

Responding to Battery Events: Time is of the Essence

Unlike standard product shipments, battery-related events demand a different level of readiness. Depending on the type of battery and the nature of the issue—whether it’s a safety recall, field failure, or test deployment—organizations must act fast while meeting strict regulatory standards.

Chris Egloff, Vice President of Strategic Opportunities at Americase, explains the challenge this way: “When a company calls us after a recall, they don’t have months. They need compliant packaging that’s been tested, certified, and ready to go—often within days.”

One solution often used in these cases is Americase’s battery bag, designed for rapid deployment. In fact, this packaging solution has been used in roughly 80% of Consumer Product Safety Commission (CPSC) recalls involving batteries over the past decade.

The Balance of Stock Readiness and Custom Fit

There’s a natural tension between speed and specificity. Off-the-shelf packaging offers immediate availability, which can be essential in time-sensitive events. But not all batteries are the same. Different chemistries, formats, and hazard classifications may require tailored containment and handling strategies.

This is where hybrid models become effective. Companies like Americase maintain extensive inventories of pre-approved solutions—but also build flexibility into their process by adapting existing designs to fit a customer’s unique battery specs, shipping routes, and compliance needs.

“Some batteries may look similar on the outside,” says Egloff, “but once you account for charge state, chemistry, and potential failure modes, the packaging often has to be adjusted to meet the specific needs and requirements.”

The Role of Testing and Scientific Validation

The science behind battery behavior—especially under stress or failure conditions—should not be underestimated. Packaging designed to contain thermal events or resist puncture and vibration must be rigorously tested and validated for the specific use case.

Real-world testing, including simulations of thermal runaway and drop/vibration impacts, plays a critical role in ensuring packaging performs as intended. These tests also provide documentation that can support regulatory compliance and risk mitigation efforts.

“Not all batteries respond the same during a failure,” Egloff notes. “Testing allows us to better understand those differences and design accordingly.”

Expert Consultation: A Prerequisite, Not an Option

In many scenarios, making the right packaging decision involves more than product selection. It requires expert consultation—on safety, on legal implications, and on the operational realities of transport and storage.

“Our job is to walk customers through the consequences of each option—both from safety and cost standpoints,” says Egloff. “And sometimes that means pointing them toward a better solution, even if we’re not the one providing it.”

Conclusion: Preparedness Starts with the Right Partnership

When timing is critical and battery risks are elevated, the most effective responses come from organizations that pair regulatory expertise with technical understanding and logistical readiness. Americase’s approach—combining a large inventory of pre-certified containers with in-house testing, customization, and regulatory expertise—illustrates how cross-functional capabilities can turn a reactive scenario into a controlled, compliant response. For companies navigating battery recalls, prototypes, or damaged goods, choosing a packaging partner that understands the full picture can make all the difference.