A similar incident in Canada<\/a> caused an estimated damage of $71,000. An electrical short circuit triggered thermal runaway, igniting lithium-ion batteries and their packaging.<\/p>\n These occurrences make proper handling non-negotiable while transporting or returning company laptops, whether to an employer, IT asset recovery provider, or refurbishment facility.<\/p>\n In this guide, we’ll explain how to evaluate returned laptops for battery damage, prepare them according to safety protocols, choose appropriate packaging, and follow applicable shipping requirements.<\/p>\n But first, let’s understand what makes lithium-ion batteries risky.<\/p>\n Lithium-ion batteries are designed to store significant energy to power laptops. However, several factors like exposure to heat, repeated charging cycles, or damage can cause them to overheat or catch fire. During laptop returns, batteries are built in, making it difficult to identify early signs of damage before shipping.<\/p>\n A laptop battery incident<\/a> during cargo handling highlights the risks of transporting these devices. In 2023, UPS personnel at a cargo facility in Louisville, Kentucky, noticed an unusual odor coming from a smoking package. The package was secured in a salvage drum, and first responders were contacted. On inspection, the package was found to contain a laptop that had experienced a thermal event.<\/p>\n This case shows why laptop returns need more than protective packaging. Businesses should check for signs of battery damage, follow the applicable shipping requirements, and ensure the carrier can accept the shipment before dispatch.<\/p>\n With each charging cycle, lithium-ion batteries tend to lose their capacity. For example, some manufacturers estimate approximately 80% capacity retention<\/a> after 300 to 500 charge cycles. This may differ by battery model and usage. However, lower capacity alone doesn’t make a battery unsafe for return transportation.<\/p>\n Assess the laptop for any signs of battery swelling or physical damage. Warning signs may look like:<\/p>\n Refrain from pressing the affected area and do not open the laptop to investigate.<\/p>\n Exposing laptops to high temperatures for longer periods, frequent heavy use, and physical impact can degrade the battery’s condition. A laptop that overheats easily may require a closer examination, even if its exterior appears normal.<\/p>\n On Windows, the powercfg \/battery report command generates a report that shows battery capacity estimates and usage history. This can help determine capacity loss, but it cannot verify whether a battery is physically safe.<\/p>\n If a laptop overheats while switched off or emits a chemical smell, it may have a battery problem. In this case, stop using it and seek guidance from a professional.<\/p>\n Packing a laptop for return shipping<\/a> isn’t as simple as wrapping it in bubble wrap. The packaging must protect the device from shocks, prevent movement inside the box, and minimize the chance of accidental activation during transit.<\/p>\n Follow the tips below to prepare the laptop for shipment:<\/p>\n Shut down the device completely instead of leaving it in sleep mode. Otherwise, movement or pressure on the power button could wake the device, leading to heat inside the package.<\/p>\n Pack the device in suitable cushioning material and place it in a sturdy box like Remote Retrieval’s purpose-built return kit which includes a specialized inflatable protective bag, padding, packing tape, and a complete guide to help employees secure their devices for transit. The box should allow the device to fit in without squeezing it.<\/p>\n The manufacturer’s original packaging is a good option if it is still intact. Sometimes retail packaging might not be able to handle shipping on its own. Therefore, according to UPS recommendations<\/a>, use double-boxing with cushioning between the inner and outer boxes. Do not use boxes with crushed corners or moisture damage.<\/p>\n Many laptops have built-in batteries that cannot be removed. Do not try removing an internal battery yourself unless you are instructed to do so. Opening the casing can damage the battery and device. If the battery is removable, follow the manufacturer’s and carrier’s instructions for that model.<\/p>\n According to IATA guidelines<\/a>, accessories like charger, adapter, and cables should be wrapped separately so they do not rub against the device. This can cause strikes during transit. Small metal objects should be packed properly, as conductive items can easily lead to a short circuit if they contact exposed battery terminals.<\/p>\n Ensure the device is dry before packing. Use a suitable protective bag to protect the device against moisture. Moisture exposure can damage the device. A sealed bag should not be considered an alternative for proper cushioning and a suitable shipping box.<\/p>\nWhat Makes Lithium-ion Batteries Risky?<\/h2>\n
How to Safely Return Laptops With Lithium-Ion Batteries<\/h2>\n
Laptop Inspection Before Returning It<\/h3>\n
Evaluate the battery’s age and usage history<\/h4>\n
Examine for swelling or physical damage<\/h4>\n
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Inspect the laptop’s operating condition<\/h4>\n
Review battery health<\/h4>\n
Do not overlook unusual heat or smell<\/h4>\n
Tips to Pack Laptops With Lithium-Ion Batteries<\/h3>\n
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Shut down the laptop<\/h4>\n<\/li>\n<\/ol>\n
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Pack the laptop using suitable packaging<\/h4>\n<\/li>\n<\/ol>\n
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Do not remove the battery unless instructed<\/h4>\n<\/li>\n<\/ol>\n
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Wrap accessories separately<\/h4>\n<\/li>\n<\/ol>\n
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Protect the device against moisture<\/h4>\n<\/li>\n<\/ol>\n
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Correctly label the devices<\/h4>\n<\/li>\n<\/ol>\n
![\"Lithium-Ion](\"https:\/\/www.remoteretrieval.com\/blog\/wp-content\/uploads\/2026\/10\/Lithium-Ion-Batteries.jpg\" "\\"Lithium-Ion")
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