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LAX TAKES DELIVERY OF FIRST HEAVY-DUTY ELECTRIC TRUCK

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Los Angeles World Airports (LAWA) is proud to announce the arrival of its first heavy-duty battery-electric vehicle, marking a significant step in the airport’s transition to a fully electric fleet.

The Class 8 Nikola Tre battery-electric vehicle (BEV) semi-style tractor will be used to move paving equipment, transport construction materials and pull other heavy equipment at Los Angeles International Airport (LAX) worksites. LAWA is the first government entity to take delivery of a Nikola Tre BEV, which is part of the airport’s ambitious plan to fully transition its vehicle fleet to all-electric. This also is the first zero-emission Class 8 tractor in the City of Los Angeles municipal fleet.

“By investing in the vehicles and charging infrastructure needed to support a fully electrified fleet, LAWA remains on the leading edge of sustainability and is laying the groundwork to achieve carbon neutrality from airport operations by 2045,” said Justin Erbacci, Chief Executive Officer, LAWA. “This purchase not only helps to reduce our environmental impact, but it also demonstrates our commitment to innovation and the future of transportation.”

The Nikola Tre BEV has a range of up to 330 miles on a single charge of its 733 kWh battery pack, and will use a new 75kW DC charging station being installed at LAX. The LAWA purchase qualified for a $120,000 rebate via the California Hybrid and Zero-Emission Truck and Bus Voucher Incentive Project. The truck is expected to have significantly reduced maintenance and fuel costs compared with a similarly equipped internal combustion unit.

“LAWA’s commitment to transition its fleet to fully electric is a direct reflection of the organization’s bold sustainability goals,” said Nikola President and CEO, Michael Lohscheller. “Nikola is proud to have our Nikola Tre battery-electric vehicle be the first Class 8 semi-truck to be added to the City of Los Angeles municipal fleet and play a role in their long-term sustainability goals.”

LAWA is committed to transitioning 100% of its sedan fleet to electric vehicles by 2031, and has adopted a zero-emission-first purchasing policy for other light-duty vehicles in its fleet of more than 1,100 vehicles. Currently, 41% of LAWA’s fleet is powered by alternative fuel, including 120 electric vehicle sedans, 20 articulating electric airfield buses and the addition of the heavy-duty Nikola Tre BEV. Other fully electric vehicles currently in LAWA’s fleet, or on order for delivery, include 26 Ford F-150 Lightning trucks, 10 Ford Mach E sedans, 32 new Class 4-8 trucks and up to 27 electric buses.

About Los Angeles International Airport (LAX)

LAX, the fifth-busiest airport in the world in 2021 with 48 million passengers, is in the midst of a multi-billion-dollar capital improvement program that will touch on all nine passenger terminals and build new facilities, including an Automated People Mover (APM) train, Consolidated Rent-A-Car (ConRAC) facility and the West Gates at Tom Bradley International Terminal.

In 2019, LAX served nearly 88.1 million passengers and offered an average of 700 daily nonstop flights to 113 destinations in the U.S. and 1,200 weekly nonstop flights to 91 markets in 46 countries on 72 commercial airlines.

LAX generates 620,600 jobs in Southern California, with labor income of $37.3 billion and economic output (business revenues) of more than $126.6 billion, according to an economic study based on 2014 operations. This activity added $6.2 billion to local and state revenues and $8.7 billion in federal tax revenues. The study also reported that LAX’s ongoing capital improvement program creates an additional 121,640 annual jobs with labor income of $7.6 billion and economic output of $20.3 billion; $966 million in state and local taxes; and $1.6 billion in federal tax revenues.

LAX is part of a system of two Southern California airports – along with Van Nuys general aviation – that are owned and operated by Los Angeles World Airports (LAWA), a proprietary department of the City of Los Angeles that receives no funding from the City’s general fund.

LAWA is leading the aviation industry in sustainability practices, with initiatives related to water management, energy (electricity) management, air quality, recycling and natural resources management. In 2019, LAX received Level III ACI Airport Carbon Accreditation from Airports Council International-Europe.

LAWA is also a leader in inclusivity, operating eight programs that provide opportunities for business enterprises including local, small, minority-owned, veteran-owned and disadvantaged firms, and working together with community partners to offer the HireLAX Apprenticeship Readiness Program, which targets local workers to make them ready for rewarding careers in the construction trades, and the Build LAX Academy, designed to prepare small contracting businesses for success when working on projects at LAX.

LAX was named a top-10 U.S. airport by SKYTRAX in 2018, and was honored as the “Most Innovative Airport for Passenger Experience” in 2019 by the American Association of Airport Executives. LAX is the second-most popular airport in the world to appear on Instagram, according to wego.com. Other recent honors have included selection as the No. 9 Best Airport (Wall Street Journal); No. 7 Best On-Time Performance for a Mega-Hub Airport (OAG); one of “The World’s Best Airports for Business Travelers” (GlobeHunters); Public-Private Partnership of the Year (P3 Bulletin); Urth Caffe, Best Airport Coffee Concession of the Year (Global FAB Awards); Innovation of the Year, Consolidated Rent-A-Car Facility (ARTBA); Best Project, United Airlines Terminal 7 and 8 Redevelopment Program (Engineering News Record California); North American Public-Private Partnership Deal of the Year (IJ Global); and Innovative Transportation Solution of the Year, Automated People Mover (WTS LA).

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How ABT CUPRA XE claimed a maiden victory in Uruguay

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NOVEMBER 27: Abt Cupra XE take 1st Position, Klara Andersson (SWE), Abt Cupra XE, and Nasser Al-Attiyah (QAT), Abt Cupra XE, win the final race during the Punta del Este on November 27, 2022. (Photo by Sam Bagnall / LAT Images)

ABT CUPRA XE collected their maiden Extreme E victory in style at the Uruguay Natural Energy X Prix, with Klara Andersson and Nasser Al-Attiyah claiming top spot at the Season 2 finale. It was the perfect end to a campaign of ups and downs.

The pairing of Andersson and Al-Attiyah have proven to be a success from the outset – after taking ABT CUPRA’s XE first Season 2 podium at the previous round in Chile. Andersson was retained for the finale in Punta del Este as Jutta Kleinschmidt continued her recovery following an accident at the Antofagasta Minerals Copper X Prix in September.

The Swedish-Qatari pair were amongst the frontrunners throughout in Uruguay. What’s more, despite her minimal experience with the team, Andersson’s times in each session were among the fastest among the female drivers.

Nasser Al-Attiyah, ABT CUPRA XE, said: “I’m just happy that we finally have our first win under our belt. We’ve been fast all season, but it has never all come together. Klara did a fantastic job, was fast, aggressive at the right moments and always stayed cool.”

However, the road to victory in Punta del Este was not without challenges. This began on Saturday; while Andersson and Al-Attiyah finished both qualifying sessions in first place, post-session time penalties dropped them back to fifth place in overall qualifying classification.

Nevertheless, ABT CUPRA XE remained in a strong position to reach the Final as they were to take on Veloce Racing and No.99 GMC HUMMER EV Chip Ganassi Racing in Semi-Final 1.

In a closely-fought race, ABT CUPRA XE were classified third on course. However, multiple penalties accrued by No.99 GMC HUMMER EV Chip Ganassi Racing throughout their run ensured that so long as Andersson and Al-Attiyah kept out of trouble they would compete in their third Final in succession. That they did, thus entering the Uruguay Natural Energy X Prix Final as one of the favourites for victory.

As the lights went out in the Final, Al-Attiyah stormed to the front and into the lead of a race that neither he nor Andersson would surrender. The pair comfortably managed a gap over nearest challengers NEOM McLaren Extreme E to take ABT CUPRA XE’s first win in the series.

Klara Andersson, ABT CUPRA XE, said: “Today is a day full of emotions for me. I’ve been following Extreme E for a long time and was hoping for my chance – now I’ve got it in this great team, and I’ve given everything to make the most of it. The success belongs to the entire team, who welcomed me so warmly and supported me together with Nasser.”

Thomas Biermaier, ABT CEO, added: “Congratulations to Klara, Nasser and the entire team in Uruguay. This triumph was overdue and highly deserved. Our whole company watched the race at home and cheered along. This was the perfect conclusion to our second Extreme E season. It’s nice to see how the series is always evolving, breaking new ground and attracting more and more attention.” 

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Guenther ends pre-season test on top

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Formula E

Maserati MSG Racing’s Maximilian Guenther capped off a dominant performance in preparation for Season 9 with another testing lap record around the Circuit Ricardo Tormo, Valencia.

The German bounded to the top of the timesheets in the final half hour of the pre-season test. The 25-year-old putting in a commanding display in his first public outing since joining the Monegasque team, leaving it to the last day to put in the best time of the week with a 1:25.127.

Another driver who has quickly acclimatised with his new surroundings at DS PENSKE was Stoffel Vandoorne, the reigning World Champion looking good to be in the fight to defend his title after this week’s running. He ended the final session a tenth behind the German’s best.

Oliver Rowland had been the form man for Mahindra Racing for the bulk of the session, setting the fastest time at the halfway stage. The British driver’s time was good enough to stick to the end and claim him third.

Putting in an impressive performance this week was Jake Hughes, the NEOM McLaren rookie only finished outside of the top 10 on one occasion this week and picked up the fourth best time in the afternoon.

Next up was Sam Bird who made it a trio of Brits in the top five as the Jaguar TCS Racing driver logged his best lap of the test on the final day. It wasn’t the same fate for Bird’s teammate Mitch Evans, last season’s runner-up brought out a red-flag after his car shut down in the closing stages.

One powertrain to rule them all?

Guenther topped every session but two this week, but there was one shared powertrain that impressed further as the mechanical assembly behind Maserati MSG Racing and DS PENSKE lead the timesheets in all but one this week.

The power behind these teams is looking to set-up an interesting software race in the new year as they target any possible edge over each other. 

At the end of the week testing is just that, testing, and we can expect more progress to be made ahead of the first round of the season as the teams pore over the data from over 5,000 laps completed around Valencia to build on their performance.

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Volvo launches more electric trucks

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Volvo launches more electric trucks
Volvo launches more electric trucks

Volvo Trucks continues to expand its range with the launch of several new electric trucks, making it possible to electrify even more transport routes in cities and regions. This latest addition of rigid* trucks further strengthens Volvo’s position as a leader in electric truck transport.

Already producing the most complete electric line up in the global truck industry, Volvo Trucks is now expanding its offering with the introduction of rigid versions of its heavy electric trucks: the Volvo FH, Volvo FM and Volvo FMX. This makes it even easier for transport companies to adopt electric vehicles in urban and regional areas.

Thanks to multiple battery, cab and chassis options, the new heavy rigid trucks can be designed to carry electric superstructures for a wide range of specialized transport assignments, including goods distribution, refuse collection and construction work. Production of the new variants will begin in the first quarter of 2023.
 

“With these new, electric trucks we are making it easier than ever for even more customers to go electric, and for cities to shift to zero-emission vehicles for virtually all transport flows. Our customers can have these trucks custom-built for their specific operation, to cut emissions while getting the same functionality as the diesel truck they are using today,” explains Roger Alm, President of Volvo Trucks.
 

Electric trucks – more attractive to both drivers and cities
Diesel trucks with heavy loads are a common sight in many cities. Now it’s possible to instead use electric trucks for these assignments. Besides producing zero exhaust emissions, electric trucks provide a better working environment for drivers as they are quiet – which also contributes to a more livable city for residents.
 

Improved customer flexibility  
The new rigid trucks have a battery capacity between 180-540 kWh. This, together with the number of batteries applied to a truck, provides for great flexibility and a wide range of potential operations.
 

“These trucks can handle all kinds of transports, from lighter to heavy loads. Customers can choose the exact battery capacity they need for their assignments, and by not carrying more batteries onboard than needed, the payload can increase. In short, we have the optimal and most cost-efficient electric transport solution, no matter what the task is,” says Roger Alm, President of Volvo Trucks.
 

Volvo Trucks is the only global truck manufacturer with a full range of electric trucks in series production already today. The company’s target is that half of its global total truck sales will be electric by 2030 at the latest.
 

*Trucks with a single rigid chassis and built-on applications such as cranes, refuse compactors and cement mixers.

Volvo FH, FM and FMX Electric rigids can be equipped as follows:

Released for sale in December 2022, serial production start March 2023:
Driveline: 490 kW

Drive unit: 3 electric motors

Battery: 450-540 kWh, 5-6 batteries

Cab: Sleeper, High, X-High sleeper cab

Wheelbase: 4300-6700

Axle Configurations: 4x2R, 6x2R, 6x4R, 8x2R, and 8x4R

PTO: Electric ePTO, Transmission PTO and Electro-Mechanical PTO

Released for sale in February, serial production start May 2023:
Driveline: 330 kW

Drive unit: 2 electric motors

Battery: 360 kWh, 4 batteries

Cab: Day cab

Wheelbase: 3900-6700
 

Released for sale in June, serial production start September 2023:
Battery: 180-270 kWh, 2-3 batteries

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SAE International publishes TIR J2954/2 for wireless charging of heavy-duty EVs; static and dynamic WPT

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wireless charging of electric vehicles
wireless charging of electric vehicles

SAE International has published the first Technical Information Report (TIR) that specifies, in a single document, both the electric vehicle- and ground-system requirements for heavy-duty (HD) wireless charging of electric vehicles (EV).

SAE TIR J2954/2 Wireless Power Transfer & Alignment for Heavy Duty Applications helps pave the way for charging HD vehicles without the need for plugging in—widely considered to be a key enabler for accelerating the adoption of EVs and autonomous vehicles. The new guideline builds off the success of the first light-duty SAE J2954 standard published in 2020. The SAE TIR J2954/2 exponentially increases the power level of Wireless Power Transfer (WPT) for heavy duty vehicles to 500 kW.

Charging a heavy-duty EV should be as simple as parking in the right spot—the wireless charging SAE TIR J2954/2 Guideline makes it possible to do that automatically.

—Jesse Schneider, chair of the SAE Wireless Power Transfer Task Force (ZEV Station)

Power is transferred by creating a magnetic resonance field between the ground transmitting assembly and a vehicle assembly fitted on the underbody of a HD vehicle. The energy crosses an air gap (the ground clearance between the pads) and is then converted from AC into DC on the vehicle to charge the vehicle batteries.

The technology is a safe and efficient method for transferring power from the AC grid supply to the HD EV. Field trials using a 10-in. (250-mm) ground clearance has shown that WPT systems operate at grid-to-battery efficiencies of 92+%. WPT with additional alignment elements in SAE J2954/2 also offers the potential to fulfill the charging requirements for autonomous EVs to charge themselves without human interaction.

The SAE TIR J2954/2 is a game-changer guideline enabling ultra-fast wireless charging to 500kW, for both trucks and buses. It also makes it possible for wireless opportunity charging at stops for buses to overnight charging without a cord and HD truck sleeper cabs. To top it off SAE J2954/2 enables dynamic wireless power transfer, making it possible to charge while driving at roadway speeds. This enables a leap forward for wireless charging for EV heavy duty vehicles by establishing a common vehicle and parking location and frequency.

Jesse Schneider

SAE TIR J2954/2 Heavy-Duty Wireless Power Transfer has the potential to change the mindset of the fleet operators enabling both transit buses and truck fleets to go electric. It makes the whole prospect of charging easier to handle compared to conductive charging.

Mike Masquelier, subteam co-chair J2954 HD WPT (WAVE)

The TIR J2954/2 is a first big step for wireless HD dynamic charging. On-the-go charging will significantly reduce vehicle battery cost, weight and provide a flexible resource to electric utilities.

Dr. Regan Zane, subteam co-chair dynamic charging (Utah State)

Additionally, SAE J2954 published an updated version 2 of its SAE J2954 light-duty standard for wireless power transfer for electric vehicles. This update improves the standard by creating requirements to assist UL 2750 in creating a certification program for SAE J2954 light-duty systems.

The SAE J2954 Standard has the potential to greatly accelerate validation and therefore commercialization of wireless charging systems for light duty vehicles.

Jesse Schneider, Chair SAE WPT Taskforce

SAE and UL signed an MoU to jointly develop and share WPT standards to help accelerate certification of wireless power transfer for electric vehicles.

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EV drivers reveal 9 tips for getting the most range out of cars in winter

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EV Driver Tips on Maximising Range in Winter
  1. Preconditioning the battery or pre-heat the cabin

Most EV drivers charge their car overnight so it’s ready for their morning journey. One Reddit user suggests to “Preheat the cabin wherever possible while plugged in. This will use energy from the grid to heat the vehicle before you drive off, rather than from the battery while you’re driving.” 

Doing so not only heats the cabin ready for the journey, it also preconditions the battery for the journey meaning it doesn’t have to use the battery while driving to get up to optimum performance temperature (generally around 20°C). 

  1. Direct heat to the passenger, not the cabin

Internal combustion engine cars have waste heat that heats the passenger cabin, but this isn’t the case in an electric vehicle and blasting the heat to compensate can reduce an EV’s performance even further in winter. 

One forum user suggests, “Instead of sacrificing warmth, use a more direct source for it. Heated seats can offer the same or better comfort than turning the heat up 5 degrees or so.” Directing the heat towards the driver via seats and a warm steering wheel is a more efficient use of the battery and consumes less energy than heating a full car cabin. 

  1. Charge according to your journey time

Another user, after driving in weathers as low as -7°C set the overnight charge to finish as close to his morning journey as possible as opposed to charging it the night before. This meant that the battery didn’t have a chance to cool before being used for the road meaning no initial loss of range before setting off. 

  1. Charge to at least 90% to compensate for loss of range 

In freezing temperatures, battery management systems onboard electric vehicles reserve about 15-20% of the overall capacity in order to keep the battery at its optimum temperature. Instead of charging the car to what you think you need, charge it up to at least 90% to allow a margin for the loss of range from increased use of HVAC and battery management. When mentioning a tip similar, one r/electricvehicles community user said, “You will need the extra juice as efficiency decreases.” 

  1. Reduce wind resistance by slowing down 

“The most important tip is to slow down!” says one Redit user, “If you just slow down a bit and go the speed limit or 5 under, your range will increase significantly.” But what’s the science behind this? The faster you go, the more wind resistance there is. Naturally, when doing higher speeds on motorways you’re using more energy to go the same distance – if you have plenty of time, look for alternative slower road routes on a GPS before embarking on your journey. 

  1. Inflate your tyres

Check your tyre pressure biweekly throughout winter and top up according to manufacturer’s recommendation when needed. An underinflated tire increases rolling resistance and consumes more energy than a correctly inflated one. Not only will they impact range, they’ll also have an impact on braking distance in potentially slippy roads. 

  1. Use Eco-Mode during low-speed journeys

Eco modes onboard electric vehicles increase efficiency by reducing sensitivity of the accelerator. As long as you’re not on busy roads or motorways where fast acceleration may be required, opt for eco mode to use less energy overall.

  1. Reduce unnecessary weight to reduce drag

Removing any considerable unnecessary weight in the boot can slightly improve your electric vehicle range. Like any vehicle, the more passengers and unnecessary cargo the less efficient the vehicle will be. If you’re guilty of leaving junk in the boot, offload anything unnecessary as every extra KG matters when getting the most from a car’s range in winter. 

Electric vehicle drivers sporting any roof boxes will not only experience a difference from the weight on their car but also the amount of drag it creates. 

9. Safely drafting behind the car in front

One Reddit user suggested, “You can really up the ante at highway speed if you tuck in behind the car in front of you,” which is a driving tactic otherwise known as drafting. Drafting refers to a leading vehicle blocking the movement of air, creating low pressure behind it. Naturally as there’s less wind resistance, you’ll consume less energy as you drive. The  2-second rule still applies when doing so as to ensure you’re not too close to the vehicle in front. 

Why does weather affect EV range? 

Rebecca Marsden, Electric Vehicle Specialist at Hippo Leasing says, “It’s widely known that cold weather can impact fuel efficiency in ICE vehicles, but the way the cold affects electric vehicles is slightly more pronounced. Operating range is one of the most important performance metrics of an electric car and lithium-ion batteries onboard it can be impacted by a drop in temperature. The ions in lithium-ion batteries, like the one onboard electric vehicles, struggle to move around in the cold. This in turn has an impact on an EV’s range overall.”

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The DS PENSKE team begins official Formula E testing and welcomes Oliver Turvey as reserve driver

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E championship

The FIA ABB Formula E championship is back with the traditional pre-season tests, which will take place from December 13-16 at the Ricardo Tormo circuit in Valencia (Spain).

As a result, the official Gen3 era finally gets going as of tomorrow. After several months dedicated to the development and fine-tuning of the third-generation Formula E car, the 11 teams entered into season 9 will face each other for the very first time over three days of official timed practice. These are key test sessions, which is why the DS PENSKE team is fielding the most decorated line-up of drivers on the entire grid, courtesy of reigning champion Stoffel Vandoorne, as well as Jean-Eric Vergne: the only double champion in the series history, who won his Formula E titles in 2018 and 2019.

Also at the test, Oliver Turvey is nominated as reserve and sporting advisor for DS PENSKE. The Englishman is a Formula 1 test driver and former factory driver in Formula E throughout eight seasons. He now brings the team the benefit of his immense experience and will take the wheel of the DS E-TENSE FE23 if any of the regular drivers are indisposed for whatever reason.

With the very first laps ready to run for the 22 third-generation Formula E cars, DS Automobiles (a two-time champion in 2019 and 2020) and PENSKE AUTOSPORT have all the tools available to battle right at the forefront of the 100% electric series.

Eugenio Franzetti, Director of DS Performance:

« Over the last few months we have been working hard to set up our DS E-TENSE FE23. The development of this third-generation Formula E car has required a lot of commitment from each and every person in the team, concentrating on the smallest details. The tests in Valencia are consequently crucial, as we will see where we stack up against the other teams for the very first time! Furthermore, we are delighted to welcome Oliver Turvey as reserve driver and sporting advisor. His huge experience in Formula E is set to reinforce what is already a super line-up within our team. »

Jay Penske, owner and Team Principal of DS PENSKE:

« Oliver not only brings incredible credentials to the team, but an acute racing intellect. He has all the qualities we were looking for with this role. He is experienced and has demonstrated his racecraft throughout the last seasons. We look forward to working with Oliver in Season 9 and beyond. »

Oliver Turvey, reserve driver and sporting adviser for DS PENSKE:

« I am delighted to be joining DS Penske as Reserve Driver and Sporting Advisor. It is a real privilege to join a championship winning team and one of the most successful manufacturers in FE’s history. I am looking forward to working closely with both JEV, Stoffel, and the whole team, using my experience in the series to help them challenge for another championship at the beginning of the Gen3 era. »

Key figures since DS Automobiles entered Formula E:

  • 89 races
  • 4 championship titles
  • 15 victories
  • 44 podiums
  • 22 pole positions
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Pole to Pole EV expedition invites children around the world to design
a flag to take to the magnetic north pole

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Pole to Pole EV Expedition

It’s time to get creative! Design a flag
to take to the North Pole

This contest is open to all children (age 14 or younger) from any country.

The Pole to Pole EV Expedition and kids news platform NewsO-Matic have
launched a holiday art challenge, inviting children around the world to submit their idea for a
flag design that will accompany the expedition team to the Magnetic North Pole, and from
the top to the bottom of the planet.


No vehicle has ever successfully driven from pole to pole and British husband and wife team
Chris and Julie Ramsey will make history next year in their all-electric Nissan Ariya,
travelling over 17,000 miles and pass through 14 countries, raising awareness of the climate
crisis and the critical role electric vehicles can play in reducing our carbon footprint.
The flag design competition is open to children under 14 years of age, and the winning
design will travel with Chris and Julie to the departure point at the Magnetic North Pole and
throughout the expedition. The winners will also receive their own flag for their school and
have the opportunity to hang out with the expedition team via video chat while they are on
their unprecedented journey.


As part of this partnership with News-O-Matic, schoolchildren around the world will be taken
on the virtual trip of a lifetime with the most exciting key moments and updates from the
expedition transmitted to the platform via regular bite-size daily stories.
Julie Ramsey said: “We are so excited to launch this competition. We believe that it is our
responsibility to inspire and educate the next generation, but we are also excited to be
inspired by your artwork from all around the world. We can’t wait to see what you come up
with and to bring the winning design with us throughout the expedition from the top to the
bottom of the world.”
Designs can be submitted via the News-O-Matic website before the competition closes at
11:59 P.M. (PST) on Tuesday, January 10, 2023. Suggested themes to inspire your design
include: Renewable Energy, Hope, Regeneration, Reforestation/Rewilding, Healthy Planet.
Electricity, Adventure and Geography.

Full details and T&Cs are available on the News-O-Matic website:
https://www.newsomatic.org/flag

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EV Market Growth Brings Lithium Battery Transport Challenges

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Lithium Battery Market
Lithium Battery Market

By Thaddeus Puccini, Senior Executive, Packaging and Global Business Development, ‎Labelmaster

It’s no secret that electric vehicles (EVs) are here to stay. The global EV market is expected to more than triple from $105 billion in 2021 to almost $355 billion in 2028.1 The number of EVs on the road is also expected to increase dramatically – from 8.15 million vehicles in 2022 to more than 39.2 million by 2030.

These changes are also ramping up quickly. In 2021, global EV sales doubled to 6.6 million vehicles, nearly reaching the critical milestone of 10% of all new vehicles sold.3 With the passage of the Inflation Reduction Act in August 2022, and California announcing a ban on new gas-powered cars by 2035 – with Washington, Massachusetts, New York, Oregon and Vermont likely following – EV sales in the U.S. could accelerate even further.

The diversity in EVs includes commercial tractors and transport vehicles, SUVs, sports cars and consumer level pickup trucks. However, the major commonality between all the vehicles is the power source of large-format lithium-ion batteries. Transporting these batteries and following all government-issued rules and regulations can be somewhat challenging to say the least.

The ongoing transport of new, end-of-life and damaged battery modules through the supply chain can be a complicated and highly regulated endeavor. And with nearly all automakers selling or unveiling EVs, every organization in the automotive industry – from the automakers themselves to the corner repair shop – needs a plan for large-format lithium-ion battery transport. Regardless of whether an organization is ever in a position of shipping an EV battery, knowing and understanding the proper rules and regulations will prove to be very beneficial to that organization and their supply chain partners.

Why Shipping Large-Format Lithium Batteries is so Challenging

Lithium-ion batteries are also prone to “thermal runaway,” which results in a ballistic reaction followed by an immediate flame that can propagate to other cells and surrounding packaging. Lithium batteries are classified as hazardous materials (hazmat)/dangerous goods (DG) and there are strict regulations that must be followed when shipping and handling them. These regulations depend on the size (watt hour) of battery and condition of battery (damaged vs. non-damaged).

Batteries that are not damaged, defective, or recalled (DDR) and have a watt-hour rating of less than 100Wh (e.g., laptop batteries) can ship as a non-fully regulated shipment by ocean or ground. And batteries with a watt-hour rating of less than 300Wh (e.g., power tools or drone batteries) can ship non-fully regulated by ground when proper labeling requirements are met.

Batteries with a watt-hour rating greater than 300Wh (such as those used in EVs), however, are considered “fully regulated class 9 shipments.” This means they must comply with all hazmat regulations for packaging, labeling, documentation, training and specified shipping methods.

Furthermore, because battery technology and safety standards are different, so too are the regulations.

Every transport mode requires compliance with a different set of regulations. This includes the 49 CFR for road and rail transport (in the U.S.), the IMDG code for vessel and maritime transport, and IATA Dangerous Goods Regulations for air transport. In many cases, lithium batteries are prohibited from being transported via air. Different countries may also have their own set of DG regulations, and must be considered.

Cargo carriers must also be considered. Even if you are 100% in compliance and the training, paperwork, and packaging are perfect, individual carriers ultimately get to decide whether to take your shipment. 

Clearly, shipping lithium batteries requires considerable resources, expertise, and planning. This is especially true when it comes to shipping DDR batteries.

Battery Transport: More Than Just a Crate

When shipping DG, organizations often think they simply need to add a new label or possibly use different packaging. But effectively and compliantly transporting lithium batteries through the supply chain requires much more. It requires understanding the complex hazmat shippingregulations, and coordinating with a variety of supply chain partners, including manufacturers, distributors, logistics providers, recyclers, carriers and more.

Whether it’s managing a large recall or the daily transport of smaller battery modules, organizations must have a plan in place to transport these complex and highly regulated goods safely and compliantly. This plan should include:

  • Knowing your batteries and the regulations that apply to them.
    Many factors impact how goods are packaged and shipped, so it’s critical to know what exactly you’re shipping, and which regulations apply. Consider the dimensions of the battery, the weight distribution, power capacity and battery status. Then be aware of the rules and regulations that govern transport (especially any shipping restrictions), including any variations between country or transportation mode and any carrier or company-specific rules, and ensure you have the proper processes and infrastructure in place to maintain compliance across the supply chain.
  • Having packaging designed, tested and ready to go. Unlike most automotive parts, large-format lithium batteries can often require custom packaging. This specialized packaging must be able to handle the size and weight of the battery being shipped while passing all UN packaging group requirement testing standards. In the case of a DDR battery, other regulations must be followed. For example, for the inner packaging, the battery must be surrounded by cushioning material that is non-combustible, non-conductive and has enough absorbent material that is equal to or greater than the amount of electrolyte inside the battery being shipped.

    When custom packaging is needed, it’s important to remember the steps that are followed. Itbegins with designing, constructing, and testing a prototype. Depending on the results of those tests, the packaging may need to be modified – and then tested all over again. The key takeaway is to ensure you have the proper packaging before you actually need the proper packaging.

    Since the packages are heavy and often asymmetrical, special equipment and training are needed to ensure safe lifting and handling. And in this case, the packaging is extremely valuable.Proper shipping, and even storage, is critical to ensuring the containers don’t get damaged.

    Establishing strong connections with supply chain partners.

    Most large-format lithium battery transportation involves more than two parties. In some cases, such as during a recall, you might have to rely on several supply chain partners to execute various stages of a battery’s journey, including battery manufacturers, automotive manufacturers, distributors, logistics providers, recyclers, carriers and more. And for the operation to becompleted on schedule, those partners must be on the same page at all times.
  • Properly training employees and partners.
    Training plays a critical role in ensuring goods are shipped safely and compliantly. Make sure all employees and relevant supply chain partners receive the necessary training – not only to comply with hazmat training mandates but also to prepare them to do their jobs correctly. Incorporating digital and elearning tools helps train workers remotely and are often more interactive and effective than more traditional methods.

Proactively Prepare for a Lithium Battery Recall

Most automakers likely have some plans in place for transporting large-format lithium-ion batteries, especially if they’re already selling electric vehicles. Unfortunately, recalls are unplanned and challenging events that companies across the supply chain are not typically ready for, and for which they often make mistakes that cost time and money, and put them at risk.

With large-format lithium batteries, it’s essential to have a plan in place to deal with potential issues before they become real problems. That plan encompasses all the basic compliance and transport requirements, along with making sure the organization is prepared for the following items in advance:

  • Determining which batteries (or cellular module assemblies—a.k.a. CMAs) can be re-used (if any), and which need to be recycled. 
  • Designing, testing, building and sourcing packaging systems for DDR batteries. 
  • Determining which packaging components can be re-used and which need to be replaced. 
  • Identifying battery recycling partners and understanding what they will require. 
  • Ensuring regulatory compliance for every step of the program, across all transport modes and destinations. 

Driving Lithium Battery Transport Forward with a Trusted Partner

As the EV market continues to grow, understanding and managing lithium battery transport becomes increasingly critical. From large recalls to ongoing, daily transport of smaller battery modules, regulatory compliance, proper packaging, and correct shipping processes – regardless of battery status – will require time and resources that some companies may not have.

The best way to make sure all aspects of large-format lithium battery transport are covered is to find a partner who’s done it all before. A trusted partner can help companies understand and navigate every facet of the lithium battery journey – from understanding the latest regulations and the packaging process, to transport and training. Don’t discount the value of taking that burden off the internal team. A partner can also assist in evaluating whether the batteries can be reused or recycled.

And in the event of a recall, they can make sure the reverse logistics are covered. Perhaps most importantly, a partner can bring much-needed expertise to understand and help coordinate the internal supply chain.

Thaddeus Puccini is the Senior Executive, Packaging and Global Business Development for Labelmaster, where his focus is to support the safe and compliant shipping and handling of dangerous goods around the world. With an emphasis on electric vehicle batteries and other large-format lithium-ion batteries, Puccini offers the next-level sustainable and reusable packaging solutions, along with regulatoryconsulting services that meet the exact needs of any organization. 
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