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The number of incidents involving lithium-ion batteries in air freight has increased by 40% over the past five years. This is according to a recent report published by UL Standards & Engagement (ULSE). The rise in incidents is linked to the growing demand for battery-powered products.
The findings are based on data from ULSE’s Thermal Runaway Incident Program database, as well as interviews and focus groups conducted with various stakeholders in the air freight industry. These include cargo airlines, regulatory authorities, manufacturers, shippers, and individual senders worldwide. The report highlights the reasons for the ongoing increase in thermal runaway incidents, the risks in the supply chain, and the fragmented oversight that allows unsafe shipments to be transported across borders undetected.
Bob McClelland, Head of Transportation Safety at ULSE, stated: “Lithium batteries are an essential part of modern life, but they also pose a growing and avoidable risk in air freight. The increase in incidents is not coincidental – it reflects identifiable gaps in battery quality, shipper awareness, regulatory oversight, and accountability in the supply chain. These systemic weaknesses need to be addressed more effectively to reverse this concerning trend.”
Causes, Risks, and Recommendations
The report identifies several key factors contributing to the rise in incidents. Firstly, the quality of batteries and the behavior of shippers are critical risk factors. Smaller shippers often lack the necessary expertise in handling hazardous materials and rely on transport providers to identify errors. This inadequate oversight and uneven enforcement of regulations result in cargo airlines having to manage risks they did not cause and often cannot fully recognize.
Geographical differences also play a role in risk assessment. The quality of manufacturing, regulatory oversight, and enforcement vary significantly between regions. More than half of the incidents with known origins occur at a handful of Asian airports, contributing to the perception that geographical differences exacerbate other risks such as battery quality and shipper behavior.
The report provides three central recommendations for improving safety in air freight: First, a clear and enforceable accountability should be established throughout the entire supply chain. Second, it is important to enhance training and global coordination within the industry to reduce ambiguities and prevent errors. Third, safety and cost should be viewed as interconnected priorities to drive top-down solutions.
