Battery Packaging Market (2035): CATL, Amcor, Nefab, EV Battery Safety, Sustainable Packaging and Global Supply Chain Growth

The Battery Packaging Market is valued at US$39.5 billion in 2025 and is projected to reach US$116.45 billion by 2035, growing at a CAGR of 11.6% during 2026-2035.DataM Intelligence has released its latest "Battery Packaging Market Size 2026" report, offering insights into market trends, competitive developments, regional performance, and emerging business opportunities. The report examines market size by value and volume, CAGR forecasts, packaging technologies, material innovations, and developments across battery manufacturing and transportation. It also assesses how safety requirements, recyclable materials, and changes in battery supply chains are influencing packaging design and investment decisions.

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United States: Recent Industry Developments
✅ May 2026: EEMB Lithium Battery Packs Recalled Over Child-Resistant Packaging Failures - The U.S. Consumer Product Safety Commission (CPSC) announced a recall of approximately 312,100 EEMB lithium coin batteries sold in pouches that did not meet federal child-resistant packaging requirements. The recall highlights how packaging compliance can affect imported battery products, online sales, and manufacturers' responsibilities under Reese's Law.

✅ November 2025: Great Lakes Wholesale Recalls Battery Packs Over Packaging Violations - The CPSC announced the recall of approximately 32,600 button-cell and coin-battery packs because they lacked the required child-resistant packaging and warning labels. The case underscores the importance of compliant packaging and labeling throughout the U.S. battery distribution chain, particularly for small batteries sold in multipacks.

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Key Industry Trends: Battery Packaging and Supply Chain Developments
- Reusable Packaging for Automated Battery Production: Battery manufacturers and automotive suppliers are moving beyond disposable foam trays toward engineered plastic packaging that maintains dimensional accuracy during repeated use. Nefab highlights that consistent tray dimensions, stackability and durability are increasingly important as automated production lines handle higher volumes of lithium-ion battery components.

- Battery Transport and End-of-Life Logistics: Packaging requirements are becoming more specialized for batteries being shipped for recycling, repair, second-life use or disposal. Nefab's standardized solutions cover different battery conditions, including damaged or defective batteries, with packaging designed to comply with applicable dangerous-goods transport rules.

- EU Battery Passport Readiness: On August 21, 2026, the European Commission published updated guidance identifying the data requirements for digital battery passports. From February 18, 2027, passports will be required for electric-vehicle batteries, light means of transport batteries and industrial batteries exceeding 2 kWh placed on the EU market or put into service. This creates a practical need for stronger battery identification, traceability and data coordination across the supply chain.

Top List of Key Players
Heitkamp & Thumann Group, United Parcel Service (UPS), Amara Raja Batteries Limited, Coveris Holdings S.A., Graphic Packaging International, Amcor Rigid Plastics USA, Inc., Tesla, Inc., DHL, Umicore and Veolia Environnement S.A.

Key Industry Developments 2026
✅ August 2026: European Commission Updates Digital Battery Passport Guidance - On August 21, the European Commission published updated guidance outlining 71 data points relevant to electric-vehicle, light-transport and industrial battery passports. The guidance helps businesses identify applicable information requirements ahead of the February 2027 implementation date, increasing the importance of traceable battery identification and coordinated supply-chain records.

✅ July 2026: EU Digital Product Passport Registry Becomes Operational - The European Commission's digital product passport registry became operational on July 20, 2026. The registry is part of the infrastructure supporting battery passport implementation, creating a new compliance milestone for businesses preparing battery identification systems and digital product records.

✅ May 2026: Nefab Demonstrates Reusable Packaging for Lithium-Ion Battery Modules - Nefab reported a returnable packaging solution developed for a major automotive supplier that replaced heavy steel pallets and a complex repacking process with a unified hybrid design. According to the company, the solution reduced carbon emissions by 76% and generated annual savings exceeding €140,000, highlighting the commercial value of improving packaging efficiency across repeated battery-component shipments.

✅ March 2026: Amcor Secures UN Certification for Recycled-Content Industrial Containers - Amcor announced UN certification for its 5.5-litre and 5.8-litre industrial containers manufactured in Pamplona, Spain, using 50% post-consumer recycled plastic. Although the certification covers hazardous-goods packaging rather than battery packs specifically, it demonstrates how recycled materials can be incorporated into certified industrial packaging while maintaining transport-safety requirements.

✅ 2026: Nefab Highlights the Shift Toward Precision-Engineered Battery Packaging - Nefab's industry analysis describes how high-volume battery production is changing packaging specifications. Thermoformed trays can provide a flexible option during production ramp-up, while injection-moulded packaging offers tighter dimensional tolerances and greater consistency for automated, high-throughput operations. This shifts purchasing decisions toward durability, repeat-use performance and total lifecycle cost rather than unit price alone.

How Our Market Research Process Works 2026-2033:
The Battery Packaging Market report by DataM Intelligence provides an in-depth assessment of the industry, supported by primary and secondary research. It examines developments in battery protection, transport packaging, thermal management, material selection, and regulatory compliance across electric vehicles, consumer electronics, and energy storage applications. The report also evaluates competitive strategies, supply-chain changes, emerging packaging technologies, and market opportunities, helping businesses understand evolving customer requirements and make informed investment and expansion decisions.

Latest Partnerships and Regulatory Developments in 2026:
September 2026: CATL and Kuehne+Nagel Partner on Battery Logistics - CATL and Kuehne+Nagel signed a memorandum of understanding to collaborate on battery logistics, transport electrification, and emissions reduction. Their plans include electrifying CATL's transport operations in Europe, exploring battery-swapping solutions for heavy-duty trucks in China, and developing battery recycling and aftersales support. The collaboration highlights the need for coordinated logistics and safer, more efficient battery handling across international supply chains.

September 2026: CATL and BME Advance Local Battery Pack Manufacturing in Egypt - CATL signed an agreement with Battery Manufacturing in Egypt (BME) to support local battery pack assembly through technology licensing, production equipment, and technical training. BME plans an initial annual capacity of 1 GWh, with a longer-term target of 5 GWh. The facility will initially focus on heavy-duty commercial vehicles, creating opportunities for packaging and protective systems designed for locally assembled battery packs.

August 2026: European Commission Updates Battery Passport Guidance - The European Commission published updated guidance outlining 71 data points for the digital battery passport, covering electric vehicle, light means of transport, and industrial batteries. The passport requirement is scheduled to apply from February 18, 2027, to covered EV batteries, light-transport batteries, and industrial batteries above 2 kWh. For packaging and supply-chain providers, the approaching deadline increases the importance of product identification, traceability, and coordination between physical packaging labels and digital product information.

July 2026: CATL and Alfen Announce a 5 GWh Sodium-Ion Battery Storage Partnership - CATL and Alfen announced plans to deploy 5 GWh of sodium-ion battery energy storage systems across Europe. The partnership expands their cooperation beyond lithium-ion technology and supports the development of alternative battery chemistries. Packaging manufacturers will need to account for the handling, protection, dimensions, and transport requirements of different battery formats as sodium-ion systems enter wider commercial use.

June 2026: CATL and J&T Express Expand Electric Logistics Operations - CATL and J&T Express signed a strategic cooperation agreement to deploy electric heavy-duty trucks, light-duty logistics vehicles, and electric warehouse forklifts. The initiative also includes battery-swapping infrastructure and energy storage solutions for logistics parks. The development reinforces the importance of packaging and handling systems that protect batteries during repeated loading, unloading, warehousing, and movement through high-volume logistics networks.

April 2026: CATL, BAIC Group, and CAES Develop an Integrated Battery-Swapping Ecosystem - The three companies agreed to collaborate on battery-swapping vehicle models, integrated charging and swapping infrastructure, and full-lifecycle battery management. CATL reported more than 1,470 Choco-Swap stations across 99 Chinese cities as of April 2026. As battery-swapping networks expand, reusable transport containers, standardized handling interfaces, and packaging solutions that support repeated battery movement may become increasingly relevant to fleet operators and service providers.

2026: IATA's Lithium Battery Shipping Rules Address Changing Transport Requirements - IATA's lithium battery shipping guidance incorporates updated provisions for newer battery types, including sodium-ion batteries, alongside changes to packing instructions, state-of-charge requirements, marking, and documentation. These requirements make compliance an important consideration for manufacturers shipping batteries internationally by air. Packaging suppliers must align their designs and validation procedures with the applicable transport classification, packaging performance tests, and carrier requirements.

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Japan: Recent Industry Developments
Developments relevant to battery packaging, transport safety, and sustainable battery supply chains.

✅ January 2026: Japan Implements Stricter Air-Transport Requirements for Lithium-Ion Batteries Japan Airlines Cargo announced changes to lithium-ion battery transport requirements under the 67th edition of the IATA Dangerous Goods Regulations, effective January 1, 2026. For applicable shipments under Packing Instruction 966, batteries packed with equipment must generally be offered for transport at a state of charge not exceeding 30% of rated capacity, subject to specified exceptions and approvals. This increases the importance of compliant packaging, shipment preparation, labeling, and documentation for battery manufacturers and logistics providers.

✅ June 2026: Japan Revises Its Battery Industry Strategy Japan's Ministry of Economy, Trade and Industry (METI) revised its Battery Industry Strategy into the Battery and Power Supply Industry Strategy on June 2, 2026. The updated framework identifies global oversupply and supply-chain risks while emphasizing complete power-supply systems, including applications for AI data centers, healthcare, and disaster preparedness. For battery packaging suppliers, this shift highlights the need to support different battery formats, stationary storage systems, and application-specific safety requirements.

✅ October 2025: Japan Strengthens Measures to Prevent Lithium-Ion Battery Fires Japan established an interministerial coordination framework to address lithium-ion battery risks, with its first coordination meeting held on October 31, 2025. The government highlighted the need for coordinated measures across ministries to prevent battery-related incidents. Because damaged batteries and improper handling can trigger fires during collection, storage, and waste processing, this issue reinforces the importance of protective packaging, safe handling procedures, and clear separation of used batteries throughout the supply chain. Source: Ministry of the Environment, Japan.

✅ May 2025: METI Advances Battery Passport and Sustainability Data Initiatives METI invited proposals for a project to establish the foundations for battery passport implementation, including sustainability data infrastructure. The initiative also aligns with broader efforts to improve battery reuse, recycling, and carbon-footprint assessment. As traceability requirements develop, packaging and labeling solutions may need to accommodate battery identification, handling information, and data linked to battery lifecycle management.

Key Segmentation Plannings (2026)
By Level of Packaging: Transportation Packaging, Cell and Pack Packaging

By Battery Type: Lead-acid Batteries, Lithium-ion Batteries

By Casing Type: Prismatic, Pouch, Cylindrical

By Material Type: Plastics, Cardboards, Metals

By Region: North America, Latin America, Europe, Asia Pacific, Middle East, and Africa

Key Market Drivers
• Growing Demand for Electric Vehicles (EVs) - The increasing adoption of electric vehicles is driving demand for specialized battery packaging solutions that provide protection, thermal management, and structural integrity for battery cells and modules.

• Expansion of Energy Storage Systems - Rising investments in renewable energy and grid-scale energy storage are increasing the need for durable and reliable battery packaging to ensure safe storage, transportation, and operation.

• Battery Safety and Thermal Management Requirements - Growing emphasis on preventing overheating, short circuits, leakage, and thermal runaway is encouraging the development of advanced packaging materials and designs with improved insulation and protective features.

• Advancements in Battery Technology - Continuous developments in lithium-ion batteries, solid-state batteries, and high-energy-density battery systems are creating demand for innovative packaging solutions that are lightweight, durable, and compatible with evolving battery designs.

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