Last reviewed: 13 November 2026

Returned phones, tablets, power tools and other rechargeable products can arrive with a damaged battery hidden inside the packaging. A returns team cannot judge safety merely from whether an item powers on. Swelling, impact damage, unusual heat, odour, hissing or leakage are warning signs that demand a different process from an ordinary leaking bottle of detergent.

Identify suspect items at goods-in

Train staff to inspect packaging without opening a potentially unstable item unnecessarily. A damaged lithium-ion battery can overheat or enter thermal runaway, releasing heat and flammable gases. Put a clear stop-and-escalate procedure in place for suspect returns; keep staff and combustible stock away from the affected area.

Use the organisation’s approved quarantine, monitoring and specialist collection arrangements. Do not puncture, compress, charge or attempt to discharge a damaged battery as part of ordinary returns handling.

Keep spill controls for other returned liquids

Returns facilities also handle broken cosmetics, inks, cleaning products and food liquids. A known, manageable aqueous spill may suit absorbents and absorbent socks, while compatible chemical absorbents may be required for identified cleaning agents. Unknown mixtures and flammable liquids need assessment before approach.

A spill kits can be useful near goods-in and return inspection stations, but it must not be labelled as a complete lithium-ion battery incident solution. The site should have separate instructions for electrical and fire hazards.

Storage, waste and handover

  • Keep suspect lithium products in an approved quarantine arrangement.
  • Prevent short circuits and follow packaging and transport requirements.
  • Document the product, visible damage and action taken.
  • Do not combine damaged battery waste with ordinary recyclable returns.
  • Inspect returns areas for unrelated spills and restock general spill kits.

The Environment Agency outlines storage and handling measures for waste batteries at permitted facilities in England. Adapt procedures to your site and use specialist advice for unstable batteries.