Batteries have become a central component of modern industrial and mobility strategies. They power electric vehicles, stabilize power grids and enable renewable energy to be stored. At the same time, they pose complex logistical challenges — from raw material extraction and transportation to take-back and recycling processes. Battery logistics is therefore much more than just a specialist area: it is a strategic factor in global supply chains.

1. Raw materials as a starting point: lithium, cobalt and nickel

The value chain often starts in remote locations. Lithium from Australia or South America, cobalt from Congo and nickel from Indonesia are the most important components of modern lithium-ion batteries. These raw materials place high demands on logistics:

• Continuous temperature and shock monitoring, as many precursors are reactive
• Dangerous goods classification for certain materials, such as lithium hydroxide
• Challenging infrastructure in assisted regions that extends transport routes and increases risks

The future shows a clear trend here: Companies are trying to diversify supply chains in order to reduce geopolitical dependencies — and are increasingly focusing on local processing steps to minimize the transport of sensitive substances.

2. Cell production: Highly precise and time-critical

The transport routes then lead to the growing production clusters in Europe and Asia. Cell and module production requires:

• Dust-free, controlled environments
• Just-in-time deliveries, as certain components are sensitive to moisture
• Specially equipped transports for electrolytes and cathode materials

With the expansion of European gigafactories — from Sweden to Germany — some of the logistics flows are shifting closer to the end markets. This reduces transport costs, but increases the requirements for precise material flows.

3. Battery transport as dangerous goods — a highly regulated system

Finished lithium-ion batteries are regularly subject to dangerous goods regulations. The classification is based on UN 3480 (batteries) and UN 3481 (batteries in devices). The following should be considered:

• ADR (street)
• RID (rail)
• IMDG code (sea freight)
• IATA-DGR (airfreight)

Depending on the charge level, size and damage status, there are different packaging standards. “Damaged or defective batteries” are subject to particularly strict requirements, as they can be thermally unstable. The industry is increasingly relying on:

• Pressure and temperature monitoring
• Special fire retardant packaging
• Isolated charging concepts for returns

Battery logistics is therefore always also risk management.

4. Reverse logistics: collection, repair and second life

With the ramp-up of electric mobility, the need for structured return processes is growing. Batteries are not only recycled, but are also sometimes used for second life cycles — e.g. as stationary storage systems.

This requires:

• Diagnostic processes to determine remaining capacities
• Transport solutions for used or damaged batteries
• Logistics centers with protective infrastructure

The biggest challenge: The condition of many old batteries is initially unknown. This increases the requirements for transport containers and safety precautions.

5. Recycling as a core of the future — and logistical challenge

Europe and Asia are investing massively in recycling capacities. Modern processes such as hydrometallurgical or direct recycling enable high recovery rates of nickel, cobalt and lithium.

For logistics, this means:

• Collection and bundling processes for end-of-life batteries
• Transport of dangerous goods via regional collection points
• Close collaboration between workshops, OEMs and recyclers

The transportation of damaged batteries remains the most critical point — thermally unstable modules require special, certified containers and often individual risk analyses.

6. Digitalization as a catalyst

Digital consistency is a big step in the coming decade:

• Lifecycle tracking from production to recycling
• Digitized dangerous goods documents (e.g. e-CMR)
• Sensors in transport boxes for real-time monitoring
• Automated reports to waste disposal companies and authorities

This not only makes battery logistics safer, but also more predictable and sustainable.