ELECTRIC VEHICLE BATTERY PACKAGING SOLUTIONS FOR THE U.S. MARKET
Lithium-ion batteries used in electric and hybrid vehicles require specialized packaging due to their classification as hazardous materials under U.S. and international transport regulations. At Söhner & Sapperplastics we specialize in reusable plastic packaging engineered to meet the strict safety standards for transporting lithium-ion batteries. From standardized shipping containers to custom load carriers, our solutions are designed to protect your battery systems while maximizing efficiency across your supply chain.
MegaPack UN: Heavy-Duty, Compliant, and Cost-Effective
Our foldable, stackable MegaPack UN containers are built for demanding applications and have been repeatedly certified for transporting hazardous goods, including Lithium-ion batteries. Whether you’re shipping individual battery modules or multi-layered battery packs, our containers offer secure, scalable protection.
We also design custom plastic inner packaging to ensure optimal cushioning, moisture resistance, and structural integrity – tailored to your specific battery configuration.
Why U.S. Manufacturers and Distributors Choose Us
- Maximize Payload Efficiency: Get more out of every shipment with optimized load volume and truck capacity.
- Minimize Damage Risk: Durable packaging reduces impact-related damage during handling and transit.
- Moisture-Proof Protection: Non-corrosive materials safeguard batteries from humidity and environmental exposure.
- Regulatory Compliance: Fully aligned with U.S. DOT and international hazardous material transport standards.
Downloads
MegaPack UN (2800 x 1800 x 827 mm)
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MegaPack UN (2250 x 1140 x 635 mm)
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MegaPack UN (1700 x 1140 x 1157 mm)
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MegaPack UN (1495 x 1140 x 635 mm)
Download (PDF: 548 KB)
MegaPack UN (1200 x 1000 x 1000 mm)
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MegaPack UN (1200 x 800 x 932 mm)
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MegaPack UN (1140 x 595 x 635 mm)
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MegaPack XXL: Engineered to handle the transport of complete vehicle battery systems
The MegaPack XXL container from Söhner is specifically engineered to handle the transport of complete vehicle battery systems, making it suitable for a wide range of EV battery types — especially those that are large, heavy, and classified as hazardous goods.
Compatible EV Battery Types
Based on its specifications and certifications, the MegaPack XXL can safely accommodate:
Lithium-Ion Battery Packs
- Common in most electric and hybrid vehicles
- Includes cylindrical, prismatic, and pouch cell formats
- Suitable for LFP, NMC, NCA chemistries
Nickel-Metal Hydride (NiMH) Batteries
- Used in hybrid vehicles like the Toyota Prius
- Lower energy density, but still hazardous
Sodium-Ion Batteries
- Emerging tech with lower thermal risk
- Compatible due to modular pack design and stable chemistry
Solid-State Battery Prototypes
- Future-forward designs with simplified containment needs
- Ideal for R&D and pilot transport scenarios
Lead-Acid Batteries
- Often used in auxiliary systems or older hybrid platforms
- Requires corrosion-resistant packaging, which the MegaPack provides
Why the MegaPack XXL Works for These Batteries
- Certified for hazardous goods under LP 903, LP 904, LP 905 and special provisions SV 377, SV 387, SV 636
- High load capacity: Up to 1,100 kg payload
- Internal battery mounts and reinforced steel frame for secure transport
- Moisture-resistant materials and optional fiberglass mats for added protection
- Modular design: Accommodates both individual modules and full battery packs