Dangerous Goods Shipping

ReturnMate supports dangerous goods shipping compliance for Shopify merchants, generating transport documents prepared in accordance with the Australian Dangerous Goods Code (ADG 7.7). It auto-classifies products by SKU, generates compliant transport documents, blocks non-compliant carriers (Australia Post is automatically blocked for DG items), and applies DG surcharges — all without manual paperwork. Supported classifications include all DG classes from flammable gases (Class 2.1) through lithium batteries (Class 9).

What Are Dangerous Goods?

Dangerous goods are items that pose a risk during transport. Common examples in e-commerce returns include:

Lithium Battery Classifications

Most consumer electronics returns involve lithium batteries. Understanding the classification is essential:

UN Numbers

Packing Instructions

Configuring DG Products

Step 1: Enable DG on Product

When setting up products that require DG declarations:

1. Navigate to Settings → Product Catalog or edit via the RMA
2. Find or add the product
3. Enable Contains Dangerous Goods
4. Select the DG classification:
   • UN Number (e.g., UN3481)
   • Packing Instruction (e.g., PI966)
   • Proper Shipping Name
   • Class/Division (e.g., 9 for lithium batteries)

Step 2: Set Battery Specifications

For lithium battery products, specify:

• Battery type: Lithium-ion or Lithium-metal
• Watt-hours (Wh): For Li-ion batteries
• Lithium content (g): For Li-metal batteries
• Number of batteries: Per unit
• Packed with or contained in: Equipment relationship

Carrier DG Support

Not all carriers or service levels support dangerous goods. ReturnMate automatically restricts carrier choice for DG items:

Section I vs Section II

Lithium batteries are classified into sections based on size:

Section II (Most Consumer Electronics)

Lower-risk batteries that can ship with simplified requirements:

Lithium-ion (Li-ion):

• Watt-hours: ≤100 Wh per battery
• Cells: ≤20 Wh per cell

Lithium-metal (Li-metal):

• Lithium content: ≤2g per cell
• Lithium content: ≤4g per battery

Requirements:

• DG label on outer package
• Handling label
• No shipper's declaration required (simplified)

Section I (Larger Batteries)

Higher-risk batteries requiring full DG compliance:

• Exceeds Section II limits
• Requires full shipper's declaration
• May require DG-certified packaging
• Higher shipping costs
• Some carriers won't accept

Automated DG Declarations

When a return contains DG products, ReturnMate automatically:

1. Identifies DG items from product configuration
2. Generates a Dangerous Goods Transport Document with correct UN numbers and packing instructions
3. Applies DG labels to shipping labels where supported
4. Calculates surcharges and adds to shipping cost
5. Validates carrier acceptance before label generation

Where a carrier produces its own DG documentation (for example FedEx), ReturnMate stores the carrier's document. Otherwise ReturnMate generates the document itself, worded for the shipment's jurisdiction:

DG Label Requirements

Packages containing lithium batteries must display:

• Lithium battery handling label (Class 9 hazard label)
• UN number (UN3481 or UN3091)
• Telephone number for emergency contact
• Shipper and consignee details

Handling DG Returns

Customer Instructions

When a customer initiates a return for a DG product:

1. Clear packaging instructions are provided
2. Battery requirements specified (e.g., charge level 30%)
3. Original packaging recommended where possible
4. Damage inspection guidance for safe shipping

Warehouse Receiving

When DG returns arrive at your warehouse:

1. Inspect packaging for damage or leakage
2. Verify declarations match actual contents
3. Quarantine damaged items per safety protocols
4. Document condition with photos

Compliance Requirements

Documentation Retention

Keep records of:

• DG declarations for each shipment
• Product DG classifications
• Carrier acceptance confirmations
• Any incidents or exceptions

Training

Staff handling DG shipments should understand:

• How to identify DG products
• Proper packaging requirements
• Emergency procedures
• Carrier-specific requirements

Regulations

Australian DG shipping is governed by:

• Australian Dangerous Goods Code (ADG 7.7)
• IATA Dangerous Goods Regulations (air transport)
• Carrier-specific policies

Troubleshooting

Label Generation Fails for DG Items

Cause: Carrier doesn't support the DG classification or service level.

Solution:

1. Check carrier DG support matrix above
2. Try alternative carrier or service
3. Verify product DG configuration is correct
4. Contact carrier for specific requirements

DG Surcharge Not Applied

Cause: Product not configured as dangerous goods.

Solution:

1. Edit product configuration
2. Enable DG flag and set classifications
3. Regenerate shipping label

Customer Can't Ship DG Item

Cause: Drop-off location doesn't accept DG, or carrier restrictions.

Solution:

1. Provide alternative drop-off locations
2. Arrange carrier pickup instead
3. Use different carrier with DG support

Best Practices

• Maintain accurate product DG classifications
• Train staff on DG identification and handling
• Use carriers that support your DG requirements
• Include clear DG instructions in customer communications
• Regularly audit DG compliance and documentation
• Have procedures for damaged battery incidents

Related Articles

• Connect Carriers
• Carriers & Label Formats
• Tracking & Label Issues