Battery packaging

Solutions for the
future of
electromobility

Better climate protection, fewer emissions, less dependence on fossil fuels: mobility is being rethought across the world. Electromobility plays a crucial role in the creation of a climate-friendly transport landscape. The use of electric vehicles produces significantly less carbon dioxide (CO2), especially when powered by renewable energy.

However, the lithium-ion batteries needed for the electric and hybrid vehicles require special packaging solutions, as the batteries are classified as hazardous goods under international transport law. As a specialist in reusable plastic packaging, we develop and produce innovative battery packaging for your Li-ion batteries – from standardized transport containers to individual load carriers.

Hazardous goods container
for battery systems
and battery packs

The advantages of lithium-ion batteries cannot be denied: a high energy density with low weight, no memory effect or only a very low one, and low self-discharge. That’s why they are the preferred energy storage option for electromobility. In the event of a defect or short circuit, however, the high energy density causes very high charging and discharging currents. These can lead to uncontrolled heating and, in the worst case, to a so-called ‘thermal runaway’ causing fire and explosion.

MegaPack JUMBO and JUMBO X

Our foldable and stackable MegaPack JUMBO large load carriers were specially developed for difficult applications and have already been repeatedly approved as hazardous goods containers for the transport of lithium-ion batteries. The transport containers are suitable for both individual battery systems and battery packs shipped in multiple layers. For optimum product protection, we develop the appropriate plastic inner packaging for you at the same time. Our battery packaging complies with the current hazardous goods regulations and is specially adapted to your hazardous goods.

Go to the MegaPack JUMBO

Go to the MegaPack JUMBO X

Hazardous goods container for battery transport

Load carriers
for battery modules

Battery modules for lithium-ion batteries consist of several battery cells that are connected to each other. Their production takes place in automated assembly lines (partly under dry room or cleanroom conditions). Very high speed and precision as well as maximum cleanliness are important factors for economical production of the modules. We develop special packaging solutions for our customers that meet the high demands of module assembly.

Workpiece carrier for battery compartments

The workpiece carriers have stable frame constructions, mounts positioned with millimeter accuracy and unit-specific centering options to ensure optimum automated handling. The load carriers can be washed before being placed in the assembly line for maximum cleanliness. The plastics used are abrasion-resistant and temperature-resistant up to 60-70°C. The appropriate battery packaging in the form of a hazardous goods and transport container for shipping the modules can also be obtained from us. We can also carry out the tests and inspections for hazardous goods approval for you on request.

Go to the workpiece carriers

Workpiece carriers and magazines
for battery cells
and battery cell frames

The key component of a battery system is the battery cells that store and release the energy. Lithium-ion batteries are divided into three cell shapes: prismatic, cylindrical and pouch cells. After their production, the individual cells are assembled into cell stacks or modules and interconnected. Assembly of prismatic and cylindrical cells often takes place directly in the module, as their housing is fixed. In contrast, pouch cells have only a flexible outer film. They are additionally fixed via a cell frame.

We offer thermoformed, component-specific packaging solutions for the various cell types as well as for cell frames, cell connectors and other components.

The solutions include workpiece carriers, containers and magazines. Our battery packaging can be made from conductive plastics and protects your sensitive components from dangerous electrostatic discharges (ESD). They are also suitable for semi-automated and fully automated handling.

ESD packaging
for battery management systems

The most important electronic component in a lithium-ion battery is the battery management system (BMS), which takes over control and monitoring during charging and discharging. In addition, it acts as a communication interface between electric vehicle and accumulator. Current, voltages and temperature are measured and controlled by sensors. The BMS is thus a central component of electric vehicle safety.

This makes it all the more important to use a high-quality packaging solution that ensures the electronic system functions flawlessly throughout the entire logistics process, right up to installation. We ensure this by developing customized ESD battery packagingfor you. By using conductive or dissipative materials, our solutions not only offer the appropriate ESD protection, but also reliably protect the battery management system from mechanical stresses during storage and transport thanks to the component-specific design.

Your benefits with plastic battery packaging

The lithium-ion battery is now established as the key storage technology in electric and hybrid vehicles due to its high performance. Even electric industrial trucks, such as forklifts, tractors and pallet trucks, are increasingly powered by Li-ion batteries. To ensure that products classified as hazardous goods reach their destination undamaged, we swiftly addressed the particular logistical challenges of e-mobility. We are now able to offer you certified hazardous goods containers for battery systems as well as thermoformed load carriers for battery components, which we can tailor to your individual requirements. We will guide you from development to certification of your battery packaging.