Custom ADR Kit from 4D Box for Lithium Batteries

In the transport of dangerous goods, choosing a compliant packaging is not enough. In many cases, certified packaging must be customized to ensure safety, practicality, and full regulatory compliance.

This article explains how, starting from a 4D certified box (model OV-4D1077), we created a tailor-made kit for lithium batteries for one of our clients.

The OV-4D1077 is a box certified according to ADR, IMDG, and IATA regulations. It is made of high-strength plywood and designed for the safe transport of various types of dangerous goods, such as lithium batteries.

It is commonly used for:

Lithium batteries (UN 3480, UN 3090)
Electronic devices with lithium batteries (UN 3481, UN 3091)
Sensitive industrial components
Lithium battery prototypes

This is a solution already compliant with ADR, IMDG, and IATA, but adaptable depending on the goods.

In this specific case, the OV-4D1077 box was transformed into a complete kit with both internal and external modifications.

Custom accessories: we integrated padding and dividers designed to safely hold the contents and prevent movement during transport. These internal components are not visible from the outside, but they ensure stability and protection in line with ADR regulations.

Steel butterfly latches: the box was equipped with metal butterfly latches to provide:

Improved closure security
Easy opening and reusability
Resistance to impact and logistics handling

Benefits of custom ADR, IMDG, and IATA packaging:

Guaranteed compliance – modifications are made while maintaining UN certification validity
Tailored to the goods – packaging is configured according to the actual size and sensitivity of the contents
Enhanced safety – protection from impact, leaks, short circuits, or uncontrolled handling
Reusability – custom boxes are more durable and suitable for multiple shipping cycles

At Overpack, we design and supply certified packaging compliant with ADR, IMDG, and IATA standards, but we mainly develop custom solutions based on:

Specific transport requirements
Type of goods (e.g. batteries, infectious substances, industrial waste)
Mode and destination (road, sea, air)

We work alongside our clients to provide tailor-made UN-certified packaging with all necessary certified accessories: absorbents, liners, labels, closures, documentation.

Looking for a UN-certified box or a custom ADR kit to safely ship lithium batteries, prototypes, or hazardous waste?