Client Overview

Industry: Marine manufacturing and distribution

Company Size: Large, established player with a national and international customer base

Products: Marine engines, electronics, accessories, and power solutions

The client is a major supplier to boat builders, marinas, dealers, and recreational/commercial marine operators. They identified strong market demand for high-performance lithium-ion batteries as replacements and upgrades for traditional lead-acid systems in marine applications.

The Challenge

Lithium-ion batteries are classified as dangerous goods under international regulations. Shipping them requires specialized packaging, rigorous testing, and precise labeling to comply with:

  • UN Recommendations on the Transport of Dangerous Goods
  • U.S. Department of Transportation (DOT) regulations (49 CFR)
  • International Maritime Dangerous Goods (IMDG) Code for ocean shipments
  • IATA requirements for any air transport segments

The client had developed or sourced excellent lithium battery products but lacked expertise in corrugated carton design and compliance for hazardous materials. They faced risks of shipment delays, rejections by carriers, fines, or safety incidents. Without validated packaging solutions, they could not scale distribution confidently to dealers, service centers, and end customers across the U.S. and beyond.

The Solution

Our team partnered with the client to deliver a complete, turnkey packaging and compliance program:

  1. Custom Carton Design: We engineered robust corrugated shipping cartons optimized for lithium-ion batteries. Designs accounted for battery size variations, weight, shock/vibration resistance (critical for marine environments), and efficient palletization for warehouse and truckload shipping.
  2. UN Testing & Certification: We engaged an accredited independent testing laboratory to conduct the full suite of UN 38.3 tests required for lithium cells and batteries. This included altitude simulation, thermal cycling, vibration, shock, external short circuit, impact, overcharge, and forced discharge tests. We managed the project end-to-end, ensuring all battery configurations met the criteria for appropriate packing groups and shipping methods.
  3. Regulatory Markings & Documentation: Approved cartons were printed with required DOT hazard labels, UN numbers, proper shipping names, and handling marks. We also helped develop supporting documentation, including shipper’s declarations and emergency response information, for seamless integration into the client’s order fulfillment process.
  4. Full Product Line Rollout Support: The solution was scaled across multiple battery capacities and configurations, creating a standardized yet flexible packaging system.

Implementation

The project moved quickly from initial design reviews to certified production packaging. Our team provided training to the client’s operations and logistics staff on proper packing procedures, label application, and carrier-specific requirements. Within weeks, the client was able to ship compliant packages via ground, ocean, and limited air channels.

Results

  • Immediate Compliance: Zero regulatory holds or carrier rejections on lithium battery shipments since launch.
  • Expanded Product Line: The client successfully introduced a complete range of lithium-ion batteries tailored for marine use (starting, house, and thruster banks).
  • Sales Growth: Battery sales have boomed, becoming a significant and fast-growing revenue stream. The ability to ship directly and reliably has strengthened relationships with dealers and boat builders.
  • Operational Efficiency: Standardized cartons improved warehouse space utilization and reduced packaging material costs compared to ad-hoc solutions.
  • Risk Mitigation: The client now ships with confidence, protecting brand reputation and avoiding potential liabilities associated with dangerous goods transport.

    • Client Impact:

    "Partnering with Tripak removed a major barrier to entering the lithium battery market. Their expertise in packaging design, testing coordination, and regulatory markings allowed us to focus on product quality and customer support. We’ve gone from uncertainty to a thriving lithium battery business.”

    Operations Director, Marine Manufacturer

    This project demonstrates how specialized packaging and compliance expertise can accelerate market entry for regulated products. The client transformed a complex regulatory challenge into a competitive advantage, capturing demand in the rapidly growing marine electrification segment. Ready to ship lithium batteries compliantly? Contact us to discuss your packaging, testing, and marking needs.