Denios, a key partner in the BatteReverse project, has won first place in the Fire Protection category of the GIT Security Awards 2025 for its Lithium-Ion Battery Transport Box. Designed specifically for the BatteReverse project, the box ensures the safe handling and transportation of lithium-ion batteries, including damaged or defective units, mitigating the risk of fires caused by thermal runaway.
The award-winning solution
The Denios Lithium-Ion Battery Transport Box XL is an advanced safety packaging solution designed for the secure transportation of lithium-ion batteries. It also functions as a quarantine box for defective batteries, ensuring safe handling and containment. Designed to support the BatteReverse project's efforts in enhancing the reverse logistics chain for batteries, it features:
- Thermal insulation: Contains the heat generated by a thermal runaway, preventing further escalation.
- Gas management system: Includes ventilation openings and a filter to enable pressure equalisation in case of outgassing or combustion.
- No loose filling materials: Simplifies the packing process, reducing response time in emergencies.
- Quick release fasteners: The removable hood is secured with quick-release fasteners, allowing for easy sealing and opening during transport.
- Forklift & crane compatibility: The design allows for easy handling and movement of the box using forklifts or cranes, ensuring a defined safety distance from the battery.
- Safe handling: The box ensures that no person needs to approach the battery directly during packing, further enhancing safety during handling of defective or damaged batteries.
- Real-time monitoring: Integrated with Denios' IoT platform to track temperature and gas composition, with alerts for anomalies.
Addressing growing risks in lithium-ion battery transportation
The increased use of lithium-ion batteries has brought heightened risk, especially for those in critical or damaged states. Thermal runaway, a hazardous reaction triggered by rising internal temperatures, can lead to smoke, hissing, and intense flames as cells overheat and ignite. This reaction quickly spreads from one battery cell to another, making the fire extremely difficult to control. As a result, many companies now classify batteries with unknown conditions as critical to preemptively mitigate these dangers, creating strong demand for advanced transport solutions like Denios’ award-winning box.
Denios’ transport box addresses these risks by containing hazardous conditions without the need for additional filling materials, which enhances safety and saves time in emergencies. The design allows users to load the box directly from a forklift, maintaining a safe distance and minimising handling risks when transporting potentially unstable batteries.
A step forward for BatteReverse and the EU battery value chain
The BatteReverse project focuses on improving the safety and efficiency of lithium-ion battery reverse logistics, a critical process for recycling and reusing battery materials. As the EU anticipates that 1.7 million tonnes of batteries will reach the end of their first life by 2030, initiatives like BatteReverse aim to enable these batteries to have a second or even third life, enhancing sustainability across the EU battery value chain. By incorporating Denios’ transport box into its approach, the project will enhance safety standards, particularly when dealing with batteries in unknown or hazardous conditions. The integration of a monitoring and tracking system ensures that any issues are detected and addressed in real-time, safeguarding both human and environmental health.
BatteReverse’s pilot testing of this solution will establish innovations in safety packaging to prevent at least 30 severe accidents per year, protecting workers and improving the process of EV battery transportation.
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