Dangerous yet uniquely challenging cargo: how does the logistics of battery energy storage systems work?

The energy storage sector is experiencing dynamic growth, driving increasing interest in the logistical management of various storage systems, including battery energy storage systems (BESS). The challenges associated with their transportation stem from their above-standard weight and classification as potentially dangerous goods. How do we deal with this task? What, often non-standard, measures do we take?

At Rohlig SUUS Logistics, we provided a comprehensive logistics project involving the import of battery energy storage systems from China to Poland. This also included the transport of transformer frames and additional accessories, such as battery modules, screws, nuts, cables, and spare equipment, all intended for installation purposes.

We were responsible for:

• transportation to the port of Shanghai,
• coordination of loading operations,
• sea freight to the ports of Bremerhaven (BESS) and Gdansk (other components),
• road transport from the port of Bremerhaven to Gdansk, where the cargo was stored at a designated yard,
• customs services,
• delivery to the final destination in the Pomeranian Voivodeship,
• supporting the customer in communication with the manufacturer.

Sea Freight: A Non-Standard Container and a Dedicated Service

The batteries comprising the energy storage system were placed in a specially designed 20-foot sea container. Why is this cargo classified as non-standard? The reason lies in its significant weight. The container with the batteries weighed 37.5 tons, far exceeding the structural capacity of a standard container. Despite being enclosed within a container, the shipment was treated as cargo, necessitating the use of an additional carrier. In this case, we utilized a flat rack container (without side walls or a roof).

Furthermore, due to their physical and chemical properties, the batteries are classified as potentially dangerous goods. Ships have strict limitations and capacity thresholds for such shipments. After consulting with the shipping line, we selected a service capable of accommodating this type of cargo on board.

Road Transport: Permits for Shipment

The shipment also required meeting specific requirements during the road transport phase. Firstly, we obtained the necessary permits for the transportation of heavy cargo on roads in Germany and Poland well in advance. We utilized a heavy-duty truck with a low-bed trailer featuring four axles, specifically designed for carrying heavy loads. The driver was required to have the appropriate qualifications for transporting ADR goods, and the vehicle – in accordance with regulations – had to be equipped with additional safety measures, including an increased number of fire extinguishers.
The remaining items – the transformer frame and accessories – were transported using standard procedures, both for sea and road freight, as they did not have any non-standard characteristics.

Efficient Customs Services

Our responsibility also included comprehensive customs services for the goods. To streamline the process, the customs clearance for all items was carried out simultaneously at the storage yard in Gdansk. Therefore, the transportation of the battery energy storage system from the port of Bremerhaven was conducted under the T1 procedure, which is the EU external transit. This allowed for the deferral of customs duties during transit. During the preparation phase, we also verified that the customer had the necessary documents for clearance and ensured their accuracy.
Integrated Approach

The entire operation was coordinated by the Project Cargo department at SUUS, specializing in the handling of non-standard, oversized shipments. An essential element of the project was the involvement of our local representative, who has a deep understanding of the specifics and challenges of the Chinese market. Among other responsibilities, he was in charge of verifying the goods at the manufacturer's factory and overseeing the transportation process to the port and the loading onto the ship.

"The example of transporting battery energy storage systems that we carried out perfectly illustrates how challenging logistics are for the energy storage sector. This is why customers value the support of an operator with experience in such projects. Support that is comprehensive and often goes beyond what may seem like standard procedures. The selection of appropriate freight solutions, securing transport permits well in advance, providing advisory services for customs services, and supporting communication with the manufacturer, verifying the goods, and coordinating operations in the local market – all of this contributes to the efficiency of the entire supply chain," summarizes the entire project Dawid Szyszka, Project Cargo Key Account Manager at Rohlig SUUS Logistics.