Key Takeaways
• Do not pack marzipan or spare lithium batteries in checked luggage to avoid security delays and bans in 2025.
• Lithium battery fires occur twice weekly on planes; power banks, vapes, and e-cigarettes must stay in carry-ons.
• European and U.S. airports warn travelers that dense food and batteries cause manual bag searches and missed flights.
As the summer travel season reaches its peak in July 2025, airport baggage handlers and aviation safety authorities across the United States 🇺🇸, United Kingdom 🇬🇧, and European Union are urgently warning passengers: do not pack certain items in your luggage. This warning is not just about convenience—it’s about safety, avoiding delays, and making sure your belongings arrive with you at your destination. The focus this year is on two surprising categories: dense food items like marzipan and lithium battery-powered devices. Here’s what every traveler needs to know before heading to the airport.
Why Are Airport Baggage Handlers Sounding the Alarm?
Airport baggage handlers are the first line of defense when it comes to keeping flights safe and on time. They see firsthand what causes problems at security checkpoints and in the baggage hold. This summer, they are especially concerned about two things:
- Marzipan and other dense food items that confuse X-ray scanners.
- Lithium battery-powered devices—including power banks, vapes, and e-cigarettes—that can cause fires if packed incorrectly.
With millions of people flying to popular destinations like Spain 🇪🇸, Portugal 🇵🇹, France 🇫🇷, and Italy 🇮🇹, even a small mistake can lead to big problems for travelers and airport staff.
Marzipan: The Unexpected Security Threat
Most people think of marzipan as a harmless almond treat, but airport baggage handlers say it’s a major headache for security teams. Marzipan is dense and has a texture that looks very similar to some explosives on X-ray machines. This means that if you pack marzipan in your checked luggage, your bag could be flagged for a manual search.
John, an airport baggage handler at Dublin Airport, explains:
“Don’t ever pack marzipan in your luggage. It has the same density as some explosives, so your bag will be removed and you’ll be called from the plane for a bag search. If the bag can’t be scanned automatically, it can end up in manual processing, which could mean your bag doesn’t make it to the flight.”
This isn’t just a problem in Ireland. Airports across the UK and EU are sharing this warning as travelers head out for summer holidays. If your bag is pulled for a manual search, you could face:
- Delays at security
- Being called off the plane for questioning
- Your bag missing your flight
Other baggage handler tips to avoid problems:
– Remove stickers from your luggage before security checks. Stickers can confuse the scanners.
– Don’t tie ribbons or other identifiers to your suitcase. These can also cause scanning issues and slow down the process.
Lithium Battery-Powered Devices: A Growing Danger
Lithium batteries are everywhere—inside phones, laptops, tablets, vapes, e-cigarettes, and power banks. But they can be dangerous if not handled properly. In 2025, there has been a sharp rise in battery fires on planes, known as “thermal runaway” incidents. According to the Federal Aviation Administration (FAA), there are now up to two lithium battery fires on planes every week. Most of these are caused by vapes, power banks, and laptops.
Despite clear warnings, many travelers still pack these items in their checked luggage:
- 38% of U.S. passengers admit to packing lithium-ion devices in checked bags
- 31% put vapes or e-cigarettes in checked bags—both actions are strictly forbidden
What Are the Current Rules for Lithium Batteries?
As of July 2025, the rules are:
- Spare lithium batteries (including power banks, vapes, and e-cigarettes):
- Never pack these in checked baggage. They must go in your carry-on bag or be kept on your person.
- If your carry-on is taken at the gate and put in the hold, you must remove all lithium batteries and take them into the cabin. Airlines and ground staff are now required to remind and help passengers with this at the gate.
- Devices with built-in lithium batteries (phones, laptops, tablets):
- You can pack these in both carry-on and checked baggage, but they must be protected from being turned on by accident or from being damaged.
- It’s recommended that these devices are charged to no more than 30% before flying. This is new guidance from the International Air Transport Association (IATA) and International Civil Aviation Organization (ICAO) for 2025.
- Charging Restrictions: You cannot use power banks or e-cigarettes to charge devices during the flight.
- Protection: Spare batteries must be protected from short-circuiting. This means keeping them in their original packaging, taping the ends, or putting them in a plastic bag or box.
New and Upcoming Regulations
- From January 1, 2026: Lithium-ion batteries packed with equipment or in vehicles must be at a reduced charge unless approved by authorities.
- For 2025: It’s strongly recommended (but not yet required) that lithium-ion batteries in equipment are at 30% charge or less, or have a capacity of 25% or less.
- European Aviation Safety Agency (EASA) Bulletin (May 27, 2025): Repeats the ban on spare lithium batteries in checked baggage and urges airlines to teach passengers and staff about these risks.
Other Items That Can Cause Trouble
It’s not just marzipan and lithium battery-powered devices that can get you into trouble at the airport. Many travelers are still caught out by:
- Liquids and spreadable foods: This includes things like lip gloss, liquid eyeliner, sauces, jams, or anything that can be spread, smeared, or squirted. If these are over the allowed limit, they should go in checked luggage or be left behind.
- Novelty items: Items like snow globes, Magic 8-balls, and certain lighters are banned or restricted in carry-on bags. These can trigger extra inspections or even fines.
What Happens If You Pack the Wrong Thing?
Packing the wrong item can lead to more than just a delay. Here’s what you risk:
- Delays and Missed Flights: If your bag is pulled for a manual search because of marzipan or lithium batteries, you could miss your flight or your bag might not make it onto the plane.
- Fines and Confiscations: Security agencies like the TSA are strictly enforcing the rules in 2025. If you pack something on the no-fly list, it will be taken away, and you could face fines that are higher than your ticket price.
- Safety Risks: Lithium battery fires can cause emergency landings, evacuations, and make other passengers feel unsafe about flying.
Step-by-Step: How to Avoid Problems at the Airport
To keep your trip smooth and safe, follow these steps:
- Don’t pack marzipan or other dense food items in your checked luggage.
- Remove all spare lithium batteries, power banks, vapes, and e-cigarettes from checked bags.
- Keep these items in your carry-on or on your person, and make sure they are protected from short-circuiting.
- If your carry-on is taken at the gate and put in the hold, remove all lithium batteries and take them with you into the cabin.
- Don’t pack large amounts of liquids, spreadable foods, or restricted novelty items in your carry-on.
- Remove stickers and ribbons from your luggage before checking in to avoid scanning problems.
- Check your airline’s specific rules for carry-on and checked baggage, as they may be different from TSA or international standards.
Official Resources for Travelers
For the most up-to-date information, always check official sources before you travel:
- IATA Battery Guidance (2025): For the latest rules and answers about battery transport, see the IATA Battery Guidance Document.
- EASA Safety Bulletins: European travelers can find the latest bulletins on lithium battery safety on the EASA website.
- TSA “What Can I Bring?” Page: U.S. travelers should check the TSA’s official list of prohibited and restricted items.
- Airline Customer Service: Contact your airline directly for their baggage policies and any updates.
The Role of Airport Baggage Handlers
Airport baggage handlers are not just moving bags—they are a key part of the security process. They are trained to spot items that could cause problems, and their warnings are based on real incidents. For example, when a bag containing marzipan is flagged, it can cause a chain reaction:
- The bag is pulled from the system for manual inspection.
- Security staff may have to call the passenger back from the gate or even off the plane.
- If the bag can’t be cleared quickly, it may not make it onto the flight.
This process can delay not just one passenger, but an entire flight. That’s why handlers are urging travelers to think carefully about what they pack.
Why Lithium Battery-Powered Devices Are So Dangerous
Lithium batteries can catch fire if they are damaged, short-circuited, or exposed to heat. These fires are hard to put out and can spread quickly. On a plane, this is a serious risk. In 2024 and 2025, there have been several emergency landings because of battery fires in the cargo hold.
Common mistakes travelers make:
- Packing spare lithium batteries in checked luggage.
- Leaving power banks or vapes in bags that are gate-checked.
- Not protecting battery terminals, which can cause short-circuits.
To stay safe:
- Always keep spare batteries in your carry-on.
- Use the original packaging or tape the ends to prevent short-circuiting.
- Never use power banks or e-cigarettes to charge devices during the flight.
What About Immigration and International Travelers?
For international travelers, these rules are even more important. Security standards may vary between countries, but the risks are the same. If you are flying to or from the United States 🇺🇸, the European Union, or other major destinations, you must follow the strictest rules.
- If you are stopped at security for a suspicious item, you may face extra questions or even miss your connecting flight.
- If your bag is delayed because of a manual search, it could affect your travel plans, especially if you are moving to a new country or starting a new job.
- If you are fined or have items confiscated, it could impact your immigration record or future travel.
According to analysis by VisaVerge.com, travelers who ignore these warnings are more likely to face delays, fines, and even trouble with immigration authorities. Being prepared and following the rules helps protect your travel plans and keeps everyone safe.
What’s Next? Stricter Rules and More Education
Looking ahead, travelers can expect even stricter enforcement and new rules about lithium batteries in 2026. Airlines and airports are also working to educate passengers:
- New signs and digital alerts at check-in and security.
- Staff training to help spot and explain risky items.
- More information online and in booking emails.
The goal is to reduce incidents, keep flights on time, and make air travel safer for everyone.
Final Takeaways for Summer 2025 Travelers
- Do not pack marzipan or spare lithium batteries (including power banks, vapes, and e-cigarettes) in your checked luggage.
- Follow all airline and security guidelines for carry-on and checked bags.
- When in doubt, leave the item out or pack it in your carry-on with all safety steps.
By following these simple steps, you can avoid delays, fines, and safety risks—and help make sure your summer travels are smooth and enjoyable.
For more details and the latest updates, always check the TSA’s official “What Can I Bring?” page and your airline’s website before you fly. Safe travels!
Learn Today
Marzipan → A dense almond-based confection resembling explosives on X-ray scanners, causing luggage manual searches.
Lithium Battery → Rechargeable battery type used in electronics; can cause fires if damaged or improperly packed on planes.
Thermal Runaway → A dangerous chemical reaction in lithium batteries that leads to uncontrollable fires onboard airplanes.
Carry-on Bag → A smaller piece of luggage passengers keep with them in the cabin during a flight.
Manual Search → Security procedure where bags are inspected physically after X-ray scans raise suspicion about contents.
This Article in a Nutshell
Travelers in summer 2025 must avoid packing marzipan and lithium battery devices in checked bags. These items trigger security delays, possible missed flights, fines, and fire risks. Airports across the US, UK, and EU enforce strict rules to keep flights safe, urging passengers to check up-to-date baggage policies carefully before travel.
— By VisaVerge.com
