Ethan Clarke
The cost of packaging batteries depends on the type of packaging used. The simplest and least expensive packaging for small batteries is shrink wrap or vacuum-formed plastic. For larger batteries, packaging may include strong outer packaging or protective enclosure casings, such as fully enclosed or wooden slatted crates. The cost of cardboard boxes for shipping can range from $1.10 to $1.15 for large volumes of 100,000 or more. Blister packs, which involve two types of materials (paper-based backer cards and thermoformed plastic containers), can cost about $1.65 per unit for 5,000 units.
| Characteristics | Values |
|---|---|
| Simplest and least expensive packaging for small batteries | Shrink wrap or vacuum formed plastic |
| Packaging for lithium-ion batteries weighing more than 26.5 pounds | Strong outer packaging or protective enclosure casings, like fully enclosed or wooden slatted crates, on pallets or other handling devices |
| Packaging for damaged or recalled lithium-ion batteries | Individual, non-metallic packaging with inner packaging made of non-combustible, non-conductive, and absorbent cushioning material; outer packaging must be made of metal, wooden or solid plastic box, metal, plywood, or plastic drum |
| Blister packs (1,000 units) | $2-3 per thermoform tray |
| Blister packs (5,000 units) | $1.65 per unit |
| Cardboard boxes (100,000+ units) | $1.10-$1.15 per box |
What You'll Learn
The cost of shrink wrap or vacuum-formed plastic for small batteries
The simplest and least expensive packaging for small batteries is shrink wrap or vacuum-formed plastic. The cost of packaging depends on the materials and process. For example, blister packs involve two types of materials: the backer cards that are paper-based and the blister itself, which is a thermoformed plastic container. The thermoform is the deciding factor, where 1,000 units are extremely expensive, at about $2-3 for just the thermoform tray. If you want a good price for a blister pack, you should consider buying at least 5,000 units, which would cost about $1.65 each. This is because this type of packaging also involves someone inserting your product before they seal the blister pack.
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The cost of packaging for lithium-ion batteries
For small batteries, the simplest and least expensive packaging is shrink wrap or vacuum-formed plastic. For larger batteries, strong outer packaging or protective enclosure casings, such as fully enclosed or wooden slatted crates, are required.
When it comes to shipping damaged or recalled lithium-ion batteries, individual non-metallic packaging with inner cushioning material that is non-combustible, non-conductive, and absorbent is necessary. The outer packaging must be made of metal, wooden, or solid plastic boxes, or metal, plywood, or plastic drums.
In terms of specific costs, blister packs, which involve a paper backer card and a thermoformed plastic container, can be expensive. For 1,000 units, the cost is around $2-3 per thermoform tray, while ordering at least 5,000 units can bring the price down to about $1.65 each.
Additionally, for large volumes of 100,000+ cardboard boxes, the cost per box can range from $1.10 to $1.15. This price can vary depending on the materials used and the manufacturing process.
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The cost of using insert mouldings to reduce product cost
The cost of packaging batteries depends on the type of packaging used, the volume of batteries being packaged, and the materials used. For example, the simplest and least expensive packaging for small batteries is shrink wrap or vacuum-formed plastic. On the other hand, lithium-ion batteries that weigh more than 26.5 pounds and have a strong, impact-resistant outer casing may be packed in strong outer packaging or in protective enclosure casings, like fully enclosed or wooden slatted crates, on pallets or other handling devices.
The cost of packaging also depends on the volume of batteries being packaged. For example, blister packs, which involve two types of materials (backer cards that are paper-based and the blister itself, which is a thermoformed plastic container), can cost about $2-3 per 1,000 units for the thermoform tray alone. However, if you order at least 5,000 units, the price per unit decreases to about $1.65.
Similarly, the cost of cardboard boxes can vary depending on the volume ordered. For example, for volumes of 100,000+ boxes, the price per box can be about $1.10-$1.15.
Overall, the cost of using insert mouldings to reduce product cost will depend on the specific type of battery, the volume of batteries being packaged, and the materials used for the packaging. By choosing the most cost-effective packaging option for the specific battery type and volume, manufacturers can reduce the overall cost of packaging.
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The cost of blister packs
Blister packs are a type of packaging that involves two types of materials: backer cards that are paper-based and the blister itself, which is a thermoformed plastic container. The cost of blister packs depends on the volume ordered. For example, 1,000 units are extremely expensive, at about $2-3 for just the thermoform tray. However, if you order 5,000 units, the price drops to about $1.65 per unit. This is because the manufacturer or another company must insert the product and seal the blister pack, which adds to the cost.
For reference, the simplest and least expensive packaging for small batteries is shrink wrap or vacuum-formed plastic. However, if the batteries weigh more than 26.5 pounds, they may need to be packed in strong outer packaging or protective enclosure casings, such as fully enclosed or wooden slatted crates. Additionally, lithium-ion batteries have specific shipping and packaging requirements, including individual, non-metallic inner packaging made of cushioning, non-combustible, non-conductive, and absorbent materials. The outer packaging for damaged or recalled lithium-ion batteries must be made of metal, wooden, or solid plastic boxes or drums and display specific hazard labels.
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The cost of shipping papers for damaged lithium-ion batteries
When it comes to damaged lithium-ion batteries, there are specific regulations that must be followed. These batteries may only be transported by highway, rail, or vessel, and each battery must be placed in individual, non-metallic packaging. The inner packaging must be made of cushioning material that is non-combustible, non-conductive, and absorbent. The outer packaging can be a metal, wooden, or solid plastic box, or a metal, plywood, or plastic drum. It is important to note that the outer packaging must display the verbiage "Damaged/defective lithium-ion battery" or "Damaged/defective lithium metal battery".
To keep costs down, the simplest and least expensive packaging for small batteries is shrink wrap or vacuum-formed plastic. However, for larger batteries or those with a strong, impact-resistant outer casing, stronger outer packaging or protective enclosure casings may be required, such as fully enclosed or wooden slatted crates.
Overall, the cost of shipping papers for damaged lithium-ion batteries depends on various factors, including the type of packaging used, the volume of batteries being shipped, and the specific regulations that must be followed.
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