Okay, let me be honest. If you’re shipping lithium batteries, one of the first headaches you’ll hit is this: wooden crates or pallets? On paper, both sound fine. But in real life… well, there’s more to it. A lot more.

I’ve shipped enough batteries to know that the “right” choice depends on a bunch of things—battery size, how long the sea voyage is, shipping rules, and sometimes just plain common sense.

Wooden Crates – The Safe but Expensive Option

Why you’d pick them:

• Protection: Crates are fully enclosed, so your batteries aren’t rattling around, getting wet, or getting smashed by someone dropping a box on top. Big packs—100Ah, 280Ah, 320Ah—can easily get damaged on the ocean. Trust me, even a small bump can screw up a battery.
• Easy batch management: Each crate can hold different sizes or different customer orders. Makes your life easier when you’re trying to track shipments.
• Regulations love them: Some shipping companies basically require hard crates for lithium batteries, especially high-capacity ones or those with a BMS.

Downsides:

• Pricey: Wood, labor, reinforcement, sealing—it all adds up. Custom-sized crates? Forget cheap.
• Bulky: They take more container space. Your shipping cost goes up.
• Handling: Heavy crates usually need a forklift. Don’t even think about trying to move them manually.

When crates make sense:

• Big batteries (≥100Ah)
• Custom or sensitive packs
• Export routes with strict safety rules (Europe, US, Japan)

Pallets – Cheap and Quick, But Risky

Why they’re tempting:

• Cheaper: Just a pallet and some stretch wrap. That’s it. Much cheaper than a full crate.
• Fast handling: Forklift in, forklift out. Perfect for big orders of standard batteries.
• Space-efficient: You can stack them and cram more in a container.

But here’s the catch:

• Less protection: Batteries are basically taped down. On a bumpy sea ride, they can bang around. Not ideal for big packs.
• Rules can bite you: Some carriers or ports don’t allow pallets for lithium batteries at all.
• Heat buildup: Big batteries can get warm. Pallets don’t ventilate as well as crates.

When pallets make sense:

• Small to medium standard batteries (≤50Ah)
• Cost-sensitive shipments
• Short, safe transport routes

Real-Life Takeaways

1. Safety first. If you’re shipping big packs or custom batteries overseas, crates are the safe bet.
2. Cost vs risk. Pallets save money, but the risk of damage or shipping headaches is real.
3. Hybrid approach works. Some suppliers put small crates on pallets—easy to handle, still protected.

Example: Last year, we needed to ship 48V 100Ah batteries to Germany. Tried pallets first, but the shipping company refused—dangerous goods. Switched to crates, cost went up, but everything arrived safely. Client was happy. Me? I didn’t lose sleep.

Bottom Line

• Crates = Safe, reliable, expensive
• Pallets = Cheap, fast, risky

Pick based on battery specs, shipping distance, and safety rules. Don’t just chase “cheapest” or “fastest.” Sometimes spending a little more saves a lot of headaches later.