Ask the Expert: Inside ITS Logistics’ Lithium-Ion Battery Operations with Mike Green

Lithium-ion batteries have become a critical facet of American energy, supercharging innovation across both consumer and industrial sectors. But while most organizations understand the importance of compliance, far fewer recognize the operational nuance required to ensure these sensitive materials are stored for long-term efficiency—especially within a modern, agile warehouse environment.

To explore what sets premium lithium-ion operations apart and the key factors many manufacturers overlook when building or scaling their programs, we sat down with Mike Green, Senior Director of Operations for ITS’s Battery Logistics Hubs.

Q: Mike, what makes handling lithium-ion batteries so different from standard warehouse operations?

A: Handling lithium-ion batteries requires a completely different level of precision, safety, and compliance. Every pallet we receive goes through a temperature verification process on arrival and is then included in our daily temperature monitoring program on the floor to ensure stability. Our entire operations team is trained and certified in lithium-ion battery handling, including fire response, HAZMAT awareness, and spill containment procedures.

Beyond the day-to-day operations, there’s a lot of groundwork that manufacturers often underestimate—HAZMAT certification lead times, local fire marshal reviews, and insurance compliance can significantly impact startup schedules. You can’t treat it like a normal warehouse setup; it’s a highly regulated environment where safety systems and training must come first.

Q: What are some operational factors EV battery manufacturers often overlook when setting up their supply chains?

A: One of the biggest challenges is understanding the physical infrastructure and space requirements. You can’t mix or stack different production lots or expiration dates together—each must remain isolated and move through the facility on a FEFO (First Expire, First Out) basis. That alone demands significantly more dedicated storage and staging space than a traditional operation.

There are also strict time constraints on when batteries must be tested before entering production, which means facilities need clearly defined staging, testing, and quarantine zones. Without those purpose-built areas and disciplined inventory control, it’s impossible to maintain both safety and operational flow.

Q: How do expiration dates and inventory rotation play a role in battery logistics?

A: Absolutely. Most people don’t realize that lithium-ion batteries have a shelf life—electrolytes degrade, and state of charge can’t sit indefinitely. We use FEFO (First Expire, First Out) logic in our WMS to ensure modules rotate correctly. It’s similar to how food or pharma operations manage expiration, but with higher safety stakes. FEFO rotation also ties into our maintenance charge schedule so batteries don’t fall below safe thresholds.

Q: How do expiration dates and inventory rotation play a role in battery logistics?

A: Batteries have a defined shelf life. That’s why we operate on a strict First Expire, First Out (FEFO) rotation process, much like how food or pharma products are managed.

Our system allows us to select expiration dates within a specific range which provides flexibility while maintaining compliance. This capability helps us optimize storage efficiency and ensure that material flows through the facility before reaching its critical age or charge threshold.

Q: Many companies are still designing their EV logistics programs. How is ITS different in being ready now?

A: The biggest difference is that we’re not waiting for a perfect “future” facility. We’ve already modularized our approach—small, compliant, and scalable battery-handling footprints that can be deployed quickly in Indy or Dallas. Whether it’s a 50,000-square-foot pilot or a 500,000-square-foot full-scale hub, we’ve built out the SOPs, the infrastructure, and the trained labor. We’re not theorizing—we’re executing today.

Q: What advice would you give to OEMs or suppliers just entering this space?

A: Start small, test fast, and partner with people who have the right experience. Battery logistics is a specialized discipline that doesn’t fit plug-and-play models. Having boots on the ground who understand how to operationalize safety, compliance, and throughput is what separates a working solution from a safety incident.

Supercharge Your Battery Operations with the Right Partner

ITS Logistics brings decades of experience managing complex, high-value supply chains together with purpose-built infrastructure to create innovative supply chain solutions built for disruption. Our team helps manufacturers, suppliers, and OEMs translate regulatory and safety standards into practical, scalable operations that keep pace with demand—no matter how fast the market shifts.

Reach out to us today and discover how our battery hubs can supercharge your operations.