Key Takeaways:

1. Most lithium-ion battery failures don’t happen suddenly—early warning signs often appear well before a thermal event.
2. Common red flags include rapid loss of runtime, charging inconsistencies, unexpected shutdowns, swelling, excess heat, or unusual odors.
3. Treat abnormal battery behavior as a safety signal, not routine wear-and-tear—early action can prevent serious incidents.
4. Consistent maintenance matters: proper charging practices, environmental controls, and routine inspection significantly reduce risk.
5. Battery Management Systems (BMS) help protect cells, but human awareness and discipline remain essential.
6. Improper storage and handling—such as extreme temperatures, humidity, or physical drops—can accelerate battery degradation and failure.
7. When a battery is damaged, defective, or recalled, immediate isolation in a rigid, insulated, compliant container is critical.
8. Improvised storage solutions don’t provide adequate thermal or electrical protection and increase facility-wide risk.
9. Early detection, responsible handling, and certified containment solutions work together to protect people, facilities, and supply chains.

Why Early Detection and Prevention Matter

At Americase, we approach lithium-ion battery failure prevention as a responsibility that spans industries. Lithium-ion batteries power everything from handheld warehouse scanners to critical data center backup systems, medical devices, and consumer electronics. Their efficiency and power density make them indispensable, but they also require careful attention. Most batteries don’t fail without warning. In fact, the earliest signs of instability often appear long before a thermal event occurs, which is why applying consistent lithium battery safety best practices is so important.

Early detection is especially critical because swelling, elevated heat, and unusual odors frequently precede more serious failures. Organizations that rely on safe containment systems gain an additional layer of protection, but it all starts with recognizing those early signals – and these warning signs can be very clear. 

At Americase, our work with regulated industries has shown that when organizations recognize these early signals and respond quickly, they can prevent most incidents from escalating. Early detection, responsible maintenance, controlled storage conditions, and the right containment solutions dramatically reduce risk across a battery’s lifecycle. This article outlines practical steps every organization can implement to stay ahead of battery failures and maintain a safer working environment.

How to Spot Lithium-Ion Battery Failures Before They Become Dangerous

At Americase, we believe the most effective risk mitigation starts long before a battery ever enters a containment solution. It begins with recognizing the signs that a lithium-ion battery is no longer performing the way it should. Industry data shows that the majority of lithium-ion failures exhibit performance degradation before a thermal event. That means organizations can prevent most incidents simply by paying attention to the earliest symptoms.

A battery that once lasted several days but suddenly lasts only a few hours shouldn’t be ignored. If a device won’t charge to 100 percent or starts shutting down when it still shows 30 to 50 percent charge remaining, that’s a red flag. Physical changes such as swelling on laptops, cell phones, or tablets are strong warnings that internal components are destabilizing. Smelling smoke, a sweet chemical odor, or noticing the device gets hot during normal operation also suggests something is wrong. UL Solutions reinforces this in its lithium-ion safety guidance, noting that early-stage symptoms often correlate with internal faults.

A hypothetical scenario shows how small clues can prevent major incidents. Picture a logistics manager at a busy North American fulfillment center who notices several handheld scanners shutting down unexpectedly mid-shift. Rather than sending the devices back into circulation, he treats the behavior as a potential early warning sign. He places the units in regulatory-compliant containment packaging designed to isolate suspect lithium-ion batteries until they can be evaluated.

By responding proactively instead of dismissing the malfunction as routine wear-and-tear, he prevents the possibility of a battery failure in a crowded picking environment. The lesson is simple: when lithium-powered devices behave unexpectedly, caution isn’t an overreaction, it’s a safeguard.

Identifying these signals early gives teams time to isolate a battery safely, protect employees, and prevent a problem from spreading. Building this awareness into daily operations is one of the most effective ways to reduce risk.

The Maintenance Practices That Reduce Lithium Battery Failures

Prevention is key to safety, which is why proper maintenance is fundamental to battery safety. One of the most important tools in this process is the Battery Management System (BMS). A BMS protects the cells by conditioning them along the 80–20 curve. Even if a phone or device reads 100 percent, the BMS typically limits chemical capacity to about 80 percent at the top end and prevents the battery from discharging below roughly 20 percent at the bottom. This operating window reduces internal stress.

Charging outside that range can lead to short circuits, which is why keeping batteries within the controlled range is so important. Environmental conditions matter as well. Batteries should be kept dry and protected from heat, cold, and humidity. 

Maintenance doesn’t require specialized equipment. It requires awareness and discipline. When teams consistently follow established charging patterns, environmental controls, and inspection habits, the likelihood of failure decreases significantly.

Why Storage and Handling Mistakes Can Cause Battery Failures, and How to Avoid Them

Storage and handling practices play a critical role in preventing lithium-ion battery failures. Safe storage begins with state-of-charge. Batteries shouldn’t be stored at 100 percent or at 0. A mid-range charge keeps internal chemistry stable. Environmental conditions matter just as much. Batteries prefer cool, dry spaces where they’re protected from humidity and temperature swings.

Handling errors also contribute to many failures. Dropping a battery may seem harmless, but if it lands on a wet, hot, or extremely cold surface, internal structures can deform. Dropping a battery with exposed terminals on a metal table can create a short. The U.S. Department of Energy notes the importance of mitigating these physical and environmental exposures in its battery safety resources.

Safe storage and handling protect far more than the batteries themselves. They protect facilities, workflows, and the people who rely on safe, compliant operations.

The Right Way to Isolate Damaged Lithium Batteries and Prevent Costly Incidents

Even with rigorous maintenance and proper handling, batteries occasionally become damaged, defective, or recalled. When that happens, immediate isolation is essential. Most improvised solutions such as plastic bins or cardboard boxes do not offer thermal or electrical protection. Purpose-built containment is the only reliable option.

When a battery shows failure signs, place it in a rigid, insulated container, and store it away from combustible materials. The goal is to isolate heat and prevent short circuits.

Organizations that prepare for damaged batteries with certified containment systems protect people, property, and their brand. Isolation isn’t optional. It’s the last barrier between a single damaged battery and a facility-wide safety incident.

Protecting Facilities, People, and Supply Chains

The risks associated with lithium-ion batteries are manageable when organizations know what to look for and how to respond. Early warning signs like rapid performance decline, charging inconsistencies, swelling, odors, or unusual heat are clear indicators that a battery needs attention. Routine maintenance, responsible charging practices, and environmental protection significantly reduce the chance of failure.

Safe storage and careful handling ensure that batteries stay within their preferred operating conditions. When something does go wrong, immediate isolation in a rigid, insulated, compliant container is critical. Improvised solutions don’t provide the level of thermal containment required in industrial environments.

Lithium-ion batteries will remain central to future innovation and global operations. By recognizing early failure signs, maintaining batteries correctly, storing and handling them safely, and isolating damaged units within certified containment systems, organizations can protect both people and property. Americase remains committed to supporting that mission with solutions engineered for safety, compliance, and operational efficiency.

Do you have questions about your company’s compliance? Schedule a quick call with our expert today.