Packaging Cushions for Defective Lithium-Ion Battery Transport

As a leading supplier of industrial textiles, THS Textiles is an official UK distribution partner for German manufacturer CIRRUX, providing high-performance packaging cushions designed for the safe transport of defective lithium-ion batteries.

Widely used across industries, CIRRUX provides a safer, more efficient solution than conventional fillers like sand, vermiculite or fire-protection granules. Its specialised material composition is designed specifically for the challenges of transporting high-risk lithium-ion batteries.

Core performance features include:

Chemically Inert – Stable in contact with lithium-ion battery electrolytes and other hazardous substances
Non-Flammable – Classified as non-combustible under DIN 4102
Electrically Non-Conductive – Prevents short circuits during handling and transport
High Absorption Capacity – Absorbs up to 3.49 kg/kg (electrolyte for Li-ion cells – EC/DMC)
High Elasticity of Compression – Maintains shape under pressure, delivering consistent cushioning
Lightweight – Reduces overall shipping weight
Reusable – Can be reused if undamaged by fire, minimising waste

Why CIRRUX Outperforms Traditional Fillers

Beyond its technical specifications, CIRRUX delivers benefits that outperform conventional materials:

Lower Shipping Costs – Its lightweight design helps cut freight expenses
Improved Safety – Higher absorption capacity enhances protection against electrolyte leaks
Sustainability – Its reusability reduces waste and material turnover
Operational Efficiency – Easier to handle, cleaner to use and less prone to mess or spillage during packing

Faster, Cleaner and Smarter Battery Packaging

CIRRUX packaging cushions simplify the process of sending and receiving defective batteries, providing a fast, clean and user-friendly solution. Simply place the battery in the box and position cushions on all sides, including the base and lid, to fully encapsulate the battery, then close the box. On delivery, the recipient removes the cushions and retrieves the battery, with no mess or extra handling.

Traditional granule-based packaging is slower and messier. Granules must be poured around the battery, spread evenly and the box sealed. On receipt, the recipient must extract the battery from the granules, which often stick to the battery itself, and then clean up and dispose of the granules. Granules are single-use, creating additional handling and waste.

CIRRUX cushions provide a cleaner, faster and fully reusable alternative.

ADR Compliant Packing For High Risk Battery Transport

CIRRUX meets stringent ADR cushioning material regulations, making it ideal for companies that manage the storage, handling or transport of lithium batteries.

When transporting lithium batteries by road under ADR regulations, the applicable packing instruction depends on the condition and purpose of the batteries. CIRRUX is designed to support compliance across the following:

ADR P908 – Damaged or Defective Lithium Batteries

Covers lithium ion and lithium metal cells and batteries that are damaged or defective and may present an increased safety risk during transport. These batteries must be individually protected, packed in UN-approved packaging, insulated using non-combustible, non-conductive materials and secured to prevent movement or short circuits.

ADR P909 – Batteries for Disposal or Recycling

Covers lithium batteries being transported for disposal or recycling, ensuring end-of-life batteries are packaged safely to prevent short circuits, movement and heat generation during transport.

ADR P910 – Prototype and Pre-Production Batteries

Covers prototype lithium cells and batteries, or production runs of up to 100 cells or batteries, being transported for testing or evaluation. As these products may not have completed full certification testing, enhanced packing requirements help protect against damage, movement and thermal hazards.

A Safer Alternative to Vermiculite Granules

Vermiculite granules have long been the default choice for packaging defective lithium-ion batteries, but CIRRUX outperforms it across every key measure.

	CIRRUX	Vermiculite
Weight	30-35 g/L	70-80 g/L
Absorption capacity	3,49 kg/kg	approx. 1,2 kg/kg
Compression	> 75 %	< 10 %

Beyond the numbers, CIRRUX is simply easier to work with. Vermiculite produces a dust cloud during packing and requires careful clean-up on both dispatch and receipt. CIRRUX cushions lift straight out, with no mess and no airborne particles to manage.

The weight difference matters commercially too. Since many carriers base freight rates on package weight, CIRRUX’s lighter build can reduce shipping costs compared to vermiculite, alongside the handling time saved.

Typical applications include:

Consumer Electronics Returns and Warranty Logistics: Suitable for phones, laptops, power tools and similar devices being sent back for repair, recycling or disposal.

EV, E-bike and E-scooter Incidents: Effective cushioning for battery packs involved in collisions, mechanical failures or product recalls.

Recycling and Disposal: Supports compliant transport of damaged batteries from recycling centers, warehouses and collection points.

Airline and Logistics Handling: A reliable solution for handling batteries from lost luggage or cargo, especially within airport logistics chains.

Laboratories and Testing Facilities: Enables safe movement of defective or stressed prototype batteries from testing environments.

Available Sizes

CIRRUX upholstery material is available in three standard sizes to meet the varying demands of battery pack dimensions:

CIRRUX-S: 30cm x 20cm
CIRRUX-M: 60cm x 40cm
CIRRUX-L: 100cm x 60cm

In addition, new formats, such as the upcoming “sausage” cushion, are in development to meet specialised packing needs. Custom sizes are also available on request, subject to minimum order quantities.

These flexible formats make it easy to configure protective packaging around batteries of different shapes and dimensions.

Your Trusted Supplier of Battery Transport Materials

At THS Textiles, we understand the regulatory pressures and safety concerns involved in transporting defective lithium batteries. Our partnership with CIRRUX ensures our clients get access to a tested, proven and compliant solution that outperforms traditional materials. Whether you’re operating in logistics, electronics, automotive or recycling, CIRRUX gives you a smarter and safer way to move high-risk battery products.