What makes recalls different
A recall can bring thousands of packs back over a short period, often with a known or suspected defect that raises fire risk. Unlike routine end-of-life collection, volumes are hard to predict precisely, deadlines may be set by regulators, and every unit may need to be handled as defective until proven otherwise.
Dealers and service centres are often the first point of contact, and many are not set up to store large numbers of suspect batteries. Without a plan, packs accumulate in unsuitable spaces, creating the very risk the recall aims to remove.
Preparing before a recall happens
Manufacturers can agree surge capacity with recyclers in advance, covering collection vehicles, packaging stock, quarantine storage and processing slots. Contracts should state response times and how costs are shared when volumes spike.
Dealers need simple instructions: how to isolate and store returned packs, which packaging to use, how to declare condition and how to book collection. Pre-positioned packaging at high-volume dealers shortens response times.
- Agree surge capacity and response times with recyclers
- Pre-position approved packaging at key dealers
- Designate quarantine storage with detection and separation
- Provide dealers with clear handling and booking instructions
Moving and processing recalled packs
Recalled packs that are suspected of being defective generally need to travel under the dangerous goods provisions for damaged or defective batteries, with appropriate packaging and documentation. Carriers must be told the correct classification before collection.
On arrival, packs go into quarantine until inspected. Depending on the defect, some may be repairable or suitable for testing, while others go directly to controlled recycling. Detailed records for each serial number support the manufacturer's reporting to regulators.