Lithium-ion Battery Safety Information
Why Lithium-ion Battery Safety Matters
Lithium-ion batteries have become essential to modern logistics, warehousing, transport, and manufacturing. From handheld scanners and e-pallet trucks to electric vehicles and backup storage systems, they power much of today’s operational infrastructure. However, their energy density and sensitivity to physical damage or improper charging also make them a significant fire risk.
At Palband, we take lithium-ion battery safety seriously. Our mission is to help businesses reduce that risk through smart, practical protection. Whether you’re storing damaged batteries, transporting battery-powered equipment, or dealing with returns and recycling, our FYASHIELD product range is designed to help you stay safe, compliant, and prepared.
Understanding the Risks of Lithium-ion Batteries
Lithium-ion batteries are prone to thermal runaway — a chain reaction that generates intense heat and toxic gases, often leading to fire or explosion. This can be triggered by:
- Physical damage (punctures, drops, crushes)
- Overcharging or use of incorrect chargers
- Exposure to extreme temperatures
- Manufacturing defects
- Internal short circuits
What makes lithium-ion battery fires especially dangerous is that they are self-fuelling. Traditional fire extinguishers such as CO₂ or foam are largely ineffective because the batteries generate their own oxygen once ignited.
Where the Risk Exists
If your operation involves any of the following, lithium-ion battery safety should be a priority:
- E-mobility vehicles (e-pallet trucks, e-forklifts, EVs)
- Battery-powered warehouse equipment
- Battery returns and recycling
- Damaged or end-of-life battery handling
- Storage of flammable goods near batteries
Failure to contain a lithium battery fire can result in warehouse shutdowns, vehicle loss, damage to property, injury to staff, and major insurance liability.
With growing pressure from insurers, environmental bodies, and health and safety regulators, businesses are increasingly expected to adopt best practices for lithium battery handling and storage.
The new DIN SPEC 91489:2024-11 standard outlines requirements for passive fire protection related to lithium-ion batteries. Several FYASHIELD products from Palband are manufactured using materials that conform to this standard, providing assurance to warehouse managers and compliance officers alike.
Palband’s Safety Solutions: The FYASHIELD Range
To help businesses reduce the risk of lithium battery fires, Palband offers a full suite of passive fire protection products under the FYASHIELD brand. These solutions are used across logistics, manufacturing, retail, recycling, e-mobility, and defence sectors.
Our heavy-duty, high-temperature pallet covers are designed to contain fires at their source. Manufactured using materials that withstand temperatures exceeding 1,000°C, they act as a critical first barrier to thermal runaway events.
Key benefits:
- Complies with DIN SPEC 91489:2024-11
- Double-stitched with Kevlar and stainless steel thread
- Resistant to chemicals, oils, and tears
- Available in custom sizes for IBCs, stillages, and metal cages
Ideal for storing damaged or suspect batteries in metal stillages, these liners reduce ignition risk while isolating hazardous contents from the surrounding environment.
Features include:
- Reinforced seams for mechanical stability
- Stainless steel plate lids to contain explosions
- Bespoke sizing available
Used to isolate battery fires in vehicles and mobile equipment, these blankets provide rapid response protection. Simply cover the smoking or burning unit to suppress flames and stop fire spread.
Suitable for:
- E-scooters, e-bikes, EVs, forklifts
- Battery charging stations
- Temporary isolation while awaiting fire services
Our fire-resistant containers are used for secure storage and transport of lithium-ion batteries, fireworks, and flammable substances. Options include soft-sided fabric containers and rigid metal enclosures.
Ideal for:
- Inter-site battery transfers
- Quarantine of damaged stock
Long-term storage of end-of-life batteries
These non-toxic, mineral-based granules can be used as a packing filler inside containers storing lithium batteries. In the event of thermal runaway, they smother flames, bind liquids, and filter toxic gases.
Use cases:
- Loose battery storage
- Battery recycling or disassembly
Custom containers with integrated suppression
Frequently Asked Questions (FAQs)
Not all lithium-ion hazards are the same. That’s why our technical team works closely with customers to assess risk levels, application environments, and operational constraints.
We consider:
- Type and volume of batteries
- Whether batteries are damaged or intact
- Storage conditions (indoor/outdoor, temperature exposure)
- Transit versus static storage
- Compatibility with cages, pallets, or trolleys
From a simple fireproof cover to a fully integrated containment system, we can help you design the right level of protection.
Safe lithium battery storage is not just about the right products — it also requires clear procedures and informed personnel. Palband supports clients by providing:
- Product usage training
- Risk assessments and recommendations
- Signage and labelling guidance
- Support with insurance queries
Fire incidents often occur during battery charging or handling, so we always advise teams to treat any damaged or swollen battery with caution, isolate it immediately, and follow pre-agreed protocols.
Fire safety and sustainability don’t have to be at odds. Many of Palband’s lithium battery safety products are:
- Reusable over long life cycles
- Made from recyclable or recycled materials
- Designed to minimise packaging waste
- Manufactured in the UK and EU, reducing carbon footprint
By integrating these solutions into your operation, you not only protect your workforce and assets but also strengthen your sustainability credentials.
Palband is a trusted commercial packaging supplier known for its commitment to innovation, compliance, and customer-first solutions. With decades of experience in industrial packaging and logistics, we understand the complex challenges facing today’s warehouses and transport hubs.
What sets us apart:
- Specialist knowledge of lithium-ion fire risks
- UK and EU-made solutions for rapid supply
- Fully customisable safety products
Responsive, knowledgeable support team
Ready to Improve Your Lithium Battery Safety?
Don’t leave your team, equipment, or business exposed. Whether you’re looking for a single product or a complete fire safety strategy, Palband can help.
Contact us today to request a quote, arrange a consultation, or learn more about our FYASHIELD fire protection range
PALBAND
Unit 3 Dickinson Place,
Durban Road Ind. Est.,
Bognor Regis,
West Sussex,
PO22 9QU
