How to pack your devices safely and avoid delays during the busy summer rush.

With Christmas around the corner, Kiwis are counting down to sun-soaked escapes or family reunions – but amid the excitement, it’s easy for careful packing to slip down the priority list.

If you’re flying this summer, one mispacked item can hinder your journey. During peak travel periods like the school holidays, even a small disruption can snowball into delays.

No one wants to be the reason for a plane sitting on the tarmac while a suitcase is offloaded.

In 2024, Verian Group research commissioned by the Civil Aviation Authority (CAA) found the proportion of travellers who feel safe and secure while flying is at its highest. And while specific knowledge of what can and can’t go in carry-on or checked luggage has improved, there are still areas that remain misunderstood – in particular, lithium batteries.

Airlines around the world have strengthened their lithium battery rules, making correct packing more important than ever. These are strict rules that need to be followed to ensure everyone’s safety onboard.

The first thing you need to know is exactly what a ‘lithium battery’ is. These are the most common type of battery used in modern rechargeable devices – think phones, laptops, tablets, cameras, vapes, powerbanks, wireless earbuds and headphones, and cordless tools.

All spare or loose lithium batteries must be packed in carry-on luggage only and are prohibited from checked bags. This includes powerbanks, hearing aid chargers, e-cigarettes and wireless earbuds like AirPods. Essentially, if an item functions as a powerbank, it must go in your carry-on.

Cellphones, laptops and other battery-operated electronics can travel in checked luggage, but with restrictions. The battery must be in the device it provides power to, and the device must be turned off – not in sleep or hibernation mode. This will ensure the device cannot unintentionally activate, overheat and catch fire.

Heated, battery-powered hairstyling devices – like straighteners, curling irons or brushes – are not allowed on the plane at all, unless the battery, heating element or other component can be removed.

“Make sure your lithium battery is packed according to your airline’s restrictions, not damaged in any way, and has cooled down before you put it in your carry-on,” says Warwick Burr, the General Manager of Aviation Security at the Civil Aviation Authority.

A watt hour (Wh) is how much power a battery can deliver over an hour. The common reason you would need to know the Wh of a battery is if you’re flying with a power bank or larger than normal battery, like a power tool or drone battery. You can generally find the Wh number on the label of your device or battery.

Watt-hour restrictions:

• Up to 100Wh is fine to travel in carry-on.
• Batteries between 100Wh and 160Wh must be approved by your airline to be carried. Each person is limited to a maximum of two batteries or powerbanks that exceed 100Wh.
• Above 160Wh is prohibited from travelling on an aircraft.

As lithium batteries continue to grow in popularity, so does the global aviation risk, says Burr. And that risk is very real.

Because a lithium battery is more powerful than a regular battery, it makes it more at risk of overheating and catching fire – especially if it is damaged or has been recently used and is hot to the touch.

“We don’t want that happening in the cargo hold where they are hard to reach. That’s why they must be packed in carry-on only,” Burr explains.

“Lithium batteries are also different because once they hit thermal runaway, they are much more difficult to extinguish than other battery fires. However, if a fire were to happen in the cabin, crew are trained to deal with it quickly and safely using onboard fire-suppression tools.”

A study of lithium battery-related incidents suggests that when an aircraft takes off, the noise of the engines and associated sonic vibrations may upset the batteries’ internal structure, according to a 2017 article in the CAA’s Vector magazine. This is thought to cause a battery to short circuit, heat up, and eventually catch fire.

“The likelihood of such an occurrence is still rare, but the consequences are, of course, potentially catastrophic.”

So far in 2025, the Aviation Security Service (AvSec) has removed more than 250,000 batteries from passengers’ bags at New Zealand airports. However, safety and security rely on multiple layers of protection, including you.

“It’s everyone’s responsibility to have a safe flight and that begins with what you put in your bag,” says Burr.

Most of the batteries removed from checked bags are spare lithium batteries, showing that many travellers are still unclear about the rules.

Airports take responsibility for disposing dangerous goods on behalf of passengers and airlines.

If an item is removed from your checked luggage, there is no guarantee it will be returned to you, and you may be liable for costs associated with recovering it.

Ultimately, being an informed traveller leads to safer flights and a smoother airport experience for all.

So, these holidays, double-check your luggage – it could save you, and others, a whole lot of stress.

For more information on what you can and can’t take onboard, always check with your airline or visit aviation.govt.nz/packsmart.