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From lithium batteries to luxury perfumes—here is how to ship hazardous materials without getting fined, delayed, or banned.
It’s Not Just "Chemicals" Anymore
When you hear "Dangerous Goods" (DG), you probably picture barrels of toxic sludge or radioactive waste. You probably don't picture an iPhone, a bottle of nail polish, or a can of whipped cream.
But in the eyes of a shipping carrier, they are exactly the same.
In 2026, the definition of Dangerous Goods has tightened significantly. With new IATA regulations for lithium batteries and stricter customs enforcement in the EU and US, getting it wrong doesn't just mean a returned package. It means fines ranging from $5,000 to $50,000 per violation.
If you are an e-commerce merchant, you are likely shipping DG without even knowing it. This guide is your safety manual. We will break down the 9 hazard classes, the new 2026 rules, and exactly how to pass the baton to FedEx, UPS, and DHL safely.
Do You Ship Dangerous Goods? (The "Hidden" List)
Dangerous Goods (often called Hazmat in the US) are articles or substances capable of posing a risk to health, safety, property, or the environment.
Many common e-commerce items fall into Class 9 (Miscellaneous) or Class 3 (Flammable Liquids). Check your catalog for these "hidden" hazards:
Lithium Batteries: Laptops, phones, power banks, and even "singing" greeting cards.
Aerosols: Hairspray, deodorant, whipped cream, cooking spray.
Flammable Liquids: Perfume, cologne, nail polish, rubbing alcohol, essential oils.
Flammable Solids: Matches, solid fuel starters.
Oxidizers: Hair dye, teeth whitening kits.
⚠️ The Golden Rule: Never assume an item is safe just because you bought it at a supermarket. If it can leak, explode, or burn, it needs a Safety Data Sheet (SDS).
The 2026 Regulatory Updates (What Changed?)
If you are using a guide from 2024, you are non-compliant. Here are the critical updates effective January 1, 2026, primarily driven by the 67th Edition of IATA Dangerous Goods Regulations.
1. The "30% Rule" is Now Mandatory
For air transport, lithium-ion batteries packed with equipment (UN 3481) and vehicles powered by lithium batteries (UN 3556) must now be offered for transport at a State of Charge (SoC) not exceeding 30% of their rated capacity.
- Old Rule: Recommended.
- 2026 Rule: Mandatory. If you ship fully charged power banks by air, they will be rejected.
2. New Classification for "Hybrid" Vehicles
IATA has introduced new proper shipping names for vehicles powered by multiple sources. You can no longer just declare "Vehicle." You must use specific UN numbers like:
- UN 3166: Vehicle, flammable gas powered, hybrid
- UN 3166: Vehicle, flammable liquid powered, hybrid
3. Stricter EU Import Controls
The EU has removed the customs duty exemption for parcels under €150 and is cracking down heavily on non-compliant DG imports. Expect nearly 100% digital scrutiny on inbound hazmat paperwork.
How to Pack and Label (The "Class 9" Workflow)
Getting the packaging wrong is the #1 reason for rejected shipments. Follow this 4-step workflow.
Step 1: Get the MSDS / SDS
Contact your manufacturer for the Material Safety Data Sheet (MSDS). You cannot ship without it. It will tell you the UN Number (e.g., UN 1266 for Perfume) and the Packing Group (I, II, or III).
Step 2: Choose the Right Box (UN Certification)
You cannot use a standard brown box. You need UN-Specification Packaging—boxes tested to withstand drops, pressure, and stacking.
- Look for the UN Mark on the box (e.g.,
4G/Y145/S/...). - Exception: Limited Quantity (LQ) shipments (e.g., small perfume bottles) may use strong rigid outer packaging without full UN markings, but must display the "White Square with Black Tips" diamond label.
Step 3: Labeling
Labels must be placed on a flat vertical side of the box, not wrapping around corners.
- Hazard Label: The diamond indicating the class (e.g., Red Flame for Class 3).
- Handling Labels: "Cargo Aircraft Only" (if applicable) or "This Way Up" arrows for liquids.
- UN Number: Must be marked clearly near the Proper Shipping Name.
Step 4: The Documentation
- You must generate a Shipper's Declaration for Dangerous Goods (DGD).
- Must be printed in color (red hatchings on the side).
- Must be signed by a trained employee.
Carrier-Specific Guidelines (FedEx vs. UPS vs. DHL)
Each carrier has its own "Operator Variations" that are stricter than the law.
FedEx
- Approval: You generally do not need a pre-approval contract for dry ice or UN 3373 (Biologicals), but you do for most other classes.
- Software: Handwritten forms are largely banned. You must use FedEx Ship Manager or an approved third-party API to generate compliant labels.
- Batteries: FedEx accepts Section II lithium batteries in standard "FedEx branded" boxes, but other hazmat must use your own UN packaging.
UPS
- Contract Only: You must have a "Hazardous Materials Agreement" in your contract to ship DG. You cannot just walk into a UPS Store with a hazmat package.
- PC Software: UPS requires you to use compliant software (like WorldShip or specific third-party vendors) that validates your entry against their chemical table.
DHL Express
- Strict Pre-Approval: DHL is arguably the strictest. You must be an "Approved Account" holder. They often require you to send a picture of your inner and outer packaging to their local DG expert before they authorize your first shipment.
- Limited Quantities: DHL specializes in ADR Limited Quantities (LQ) for road transport in Europe, which is cheaper and requires less paperwork.
Cheat Sheet: Common UN Numbers
FAQ: Frequently Asked Questions
What is the penalty for undeclared Dangerous Goods?
Penalties are severe. Major carriers and maritime lines charge administrative fees of $15,000 to $45,000 per container for misdeclared DG. This is on top of potential government fines and criminal liability if an accident occurs.
Can I ship Dangerous Goods via standard mail (USPS/Royal Mail)?
Generally, no for international air mail. Domestic ground services may accept Limited Quantities (like perfume) if properly labeled, but you must check specific "Publication 52" rules for USPS. Never drop a hazmat package in a street mailbox.
Do I need training to ship Dangerous Goods?
Yes. By law (ICAO/IATA and DOT), any employee who classifies, packs, marks, or signs the paperwork for DG must be trained and certified. This training must be refreshed every 24 months.
What is the difference between UN 3480 and UN 3481?
UN 3480 refers to loose batteries (e.g., a box of power banks), which are strictly regulated and often banned from passenger aircraft. UN 3481 refers to batteries contained in equipment (e.g., an iPhone), which are easier to ship as the device provides protection.
Conclusion
Shipping Dangerous Goods in 2026 is not about finding shortcuts; it's about building a repeatable, safe process. The 2026 regulations have removed the "gray area" for lithium batteries and hybrid vehicles, making compliance binary: you are either safe, or you are fined.
- Next Step: Audit your inventory today. If you need a shipping platform that helps automate carrier selection and label generation for compliant shipments, start your free trial with ShippyPro today.
As the Growth Manager at ShippyPro, I help online retailers transform their shipping operations from a bottleneck into a growth engine. My expertise lies in ecommerce logistics and automation, specifically helping brands save time and scale efficiently. I write about the tools, strategies, and technologies that are defining the future of fulfillment.