This article is based on an official press release from Shell.

Shell has officially entered into a long-term agreement to purchase sustainable aviation fuel (SAF) from Green Sky Capital, a renewable fuel developer focused on the Middle East and North Africa (MENA) region. The deal, announced recently, secures 100 percent of the output from what is slated to be Egypt’s first commercial-scale SAF production facility.

This offtake agreement provides the necessary commercial certainty for investors to proceed with the construction of the plant. According to the company’s announcement, the facility is expected to commence operations by the end of 2027. Once fully operational, it will significantly bolster the supply of low-carbon fuels in the region and support the aviation industry’s broader decarbonization goals.

Agreement Overview and Production Capacity

The partnership between Shell and Green Sky Capital marks a significant step in scaling global SAF availability. By committing to purchase the entire output of the facility, Shell is effectively de-risking the project for its developers and financiers.

Facility Specifications and Timeline

The new plant is projected to produce up to 145,000 tonnes of SAF annually. In addition to aviation fuel, the facility will generate bionaphtha and biopropane as by-products. Shell reports that the use of these fuels is expected to contribute to a yearly reduction of up to 500,000 tons of carbon dioxide equivalent (CO2e) emissions.

While specific location details were not itemized in the press statement, industry data suggests the facility will be a cornerstone of Egypt’s renewable energy infrastructure. The operational target is set for late 2027, aligning with increasing global mandates for SAF usage.

Executive Commentary

Geoff Mansfield, Vice President of Low Carbon Fuels at Shell Trading, emphasized the strategic importance of the deal in a statement included in the release:

“By securing 100% of the plant’s output, Shell is strengthening its global supply network for low-carbon fuels and helping aviation meet decarbonisation targets.”

Strategic Context and Market Position

This agreement reflects Shell’s broader strategy to become a net-zero emissions energy business by 2050. The company has been aggressively expanding its logistics and supply capabilities to meet the growing demand from airlines facing both regulatory mandates and voluntary sustainability commitments.

Shell’s Global SAF Footprint

According to data released by the company, Shell has established itself as a dominant player in the SAF market:

• Global Reach: As of July 2025, Shell delivers SAF to more than 80 locations across 18 countries.
• Market Share: In 2024, the company accounted for nearly 20 percent of total SAF sales in Europe and North America.

Shell attributes this market position to long-term agreements with producers, strong customer relationships, and strategic investments in logistics infrastructure around key airports and terminals.

About Green Sky Capital

Green Sky Capital serves as the developer for this project. It is identified as a regional renewable-fuel development platform operating within the MENA region. It is important to note that this entity is distinct from the U.S.-based fintech firm GreenSky, LLC, and the Canadian venture capital firm GreenSky Ventures. This project is part of a wider consortium often referred to as the Egyptian Sustainable Aviation Fuel Company (ESAF), involving collaboration with Egyptian state entities.

AirPro News Analysis

The Critical Role of Offtake Agreements

At AirPro News, we observe that 100 percent offtake agreements, like the one signed between Shell and Green Sky Capital, are becoming the “gold standard” for greenfield SAF projects. The primary barrier to entry for new SAF facilities is often not technology, but “bankability.” Lenders are hesitant to finance infrastructure costing hundreds of millions of dollars without guaranteed revenue streams.

By locking in a buyer for the entire 145,000-tonne capacity before the plant is even built, this deal effectively bridges the gap between planning and execution. It signals a maturing market where major energy traders are willing to bet on long-term supply rather than spot-market availability. Furthermore, locating this capacity in Egypt diversifies the global supply chain, reducing the industry’s heavy reliance on production hubs in North America and Western Europe.

Frequently Asked Questions

When will the new facility begin production?
Operations are expected to commence by the end of 2027.

How much fuel will the plant produce?
The facility is designed to produce up to 145,000 tonnes of Sustainable Aviation Fuel (SAF) annually, along with bionaphtha and biopropane.

What is the environmental impact?
The production and use of fuels from this plant are expected to reduce carbon dioxide equivalent emissions by up to 500,000 tons per year.

Who is buying the fuel?
Shell has signed a long-term agreement to purchase 100% of the facility’s output.

Sources

Shell Press Release

Investigating Aviation’s Climate Footprint: The DLR and TUI fly Collaboration

In a significant step towards understanding and mitigating the environmental impact of air travel, the German Aerospace Center (DLR) has initiated a pioneering flight campaign in partnership with TUI fly. For the first time in several years, a dedicated research aircraft is trailing scheduled passenger flights to capture real-time data on emissions. This initiative is part of the broader European research project A4CLIMATE, which aims to shed light on the complex relationship between modern engine technology and the formation of condensation trails, commonly known as contrails.

While the aviation industry has long focused on reducing carbon dioxide (CO₂) emissions, scientific consensus increasingly points to non-CO₂ effects as a major contributor to global warming. Specifically, contrails and the resulting cirrus clouds are believed to trap heat in the Earth’s atmosphere. We observe that this collaboration represents a critical shift from theoretical modeling to real-world validation, as researchers seek to determine how modern “lean-burn” engines influence the atmosphere compared to older technologies.

The campaign involves high-precision coordination between scientific pilots and commercial flight crews. By analyzing the exhaust plumes of aircraft in regular service, the project partners aim to develop robust strategies for climate-optimized flight planning. This effort highlights a growing industry trend where operational expertise and atmospheric science converge to address the urgent challenges of Climate change.

The Mission Profile: Chasing Data at 30,000 Feet

The core of this campaign features a DLR Dassault Falcon 20E research aircraft following a TUI fly Boeing 737 MAX 8. The operation requires the research plane to maintain a distance of approximately 10 kilometers (five nautical miles) behind the passenger jet. This specific distance allows the exhaust plume to evolve sufficiently for meaningful measurement while remaining fresh enough to analyze the immediate chemical and physical properties of the emissions.

The flights are currently being conducted on regular routes between Germany and Egypt. These corridors were selected due to their high probability of contrail formation, providing researchers with ample opportunities to gather relevant data. The focus of the study is the Boeing 737 MAX 8, which is equipped with modern CFM International LEAP-1B engines. These engines are characterized by their “lean-burn” combustion technology, which is designed to be more fuel-efficient and emit significantly less soot than previous engine generations.

Instruments onboard the Falcon 20E are tasked with measuring the evolution of soot and volatile particles within the exhaust plume for periods of up to 30 minutes. The primary scientific question driving this specific phase of the research is whether the reduction in soot emissions from these modern engines translates directly to a reduction in persistent contrails. While it is known that soot particles act as nuclei for ice crystals, the exact correlation between reduced soot mass and the number of ice crystals formed remains a complex variable that requires empirical verification.

“We want to understand how much global warming can be reduced when aircraft are more modern and smarter. It is still unclear whether less soot automatically means fewer contrails.”, Christiane Voigt, Project Manager at DLR Institute of Atmospheric Physics.

The Science of Contrails and Climate Impact

To understand the significance of this study, we must look at the mechanics of contrail formation. Contrails are created when hot, humid exhaust gases from aircraft engines mix with the cold air of the upper atmosphere. If the air is sufficiently cold and humid (ice-supersaturated), the water vapor condenses and freezes around particles, primarily soot, emitted by the engines. These ice crystals can persist and spread, forming cirrus clouds that prevent heat from escaping the Earth, a phenomenon known as radiative forcing.

Current scientific estimates suggest that these non-CO₂ effects could be responsible for a substantial portion of aviation’s total climate impact. Some studies indicate that contrails and contrail-induced cirrus clouds might account for up to two-thirds of the sector’s contribution to global warming, or approximately 1% to 2% of total global warming. Unlike CO₂, which remains in the atmosphere for centuries, contrails have a lifespan measured in hours. This presents a unique opportunity: if contrail formation can be prevented, the climate benefit is immediate.

However, the interaction between engine technology and atmospheric physics is not straightforward. While modern engines emit fewer soot particles, the particles that are emitted may still be sufficient to trigger contrail formation under certain conditions. Furthermore, the size and optical properties of the ice crystals formed by lean-burn engines may differ from those formed by older engines, potentially altering their warming effect. The data collected by the Falcon 20E is essential for refining climate models and verifying the accuracy of prediction tools used for flight planning.

The A4CLIMATE Project: A European Initiative

This flight campaign is a central component of the A4CLIMATE project, a major research initiative funded by the European Union. The project brings together a consortium of 17 partners from nine countries, including leading research institutions like the Max Planck Society, ETH Zurich, and Imperial College London, as well as industry heavyweights such as Airbus, Rolls-Royce, and Lufthansa Systems. The goal is to develop practical, science-based solutions to minimize the climate impact of aviation beyond simple fuel efficiency.

The A4CLIMATE strategy explores three primary avenues for mitigation. First, as demonstrated by the current TUI fly campaign, is the assessment of advanced engine technologies and their combustion characteristics. Second, the project is investigating the potential of SAF, which naturally contain fewer aromatics and therefore produce less soot, potentially reducing contrail formation further. Third, the project focuses on climate-optimized routing, or “contrail avoidance.”

Climate-optimized routing involves adjusting flight paths, often by small changes in altitude, to avoid regions of the atmosphere that are supersaturated with ice. If aircraft can fly around or above these “cold and humid” pockets, contrails can be avoided entirely. TUI fly has already been active in this area; since early 2025, the Airlines has routed several hundred flights specifically to avoid long-lasting contrails, providing operational data to researchers. The current measurement campaign serves to validate the predictions that guide these routing decisions.

“As a partner to science, we are providing our flights and our operational expertise. We want to help ensure that research results are quickly incorporated into everyday aviation practice, in order to reduce the climate impact of our flights.”, Christoph Todt, Head of Environmental Sustainability at TUI Airline.

Conclusion and Future Implications

The collaboration between DLR and TUI fly under the A4CLIMATE project marks a pivotal moment in aviation Sustainability research. By directly measuring the emissions of modern aircraft in real-world conditions, the industry is moving closer to understanding the full scope of its environmental footprint. The data gathered from these flights will be instrumental in calibrating the next generation of climate models and validating the effectiveness of new engine technologies.

Looking ahead, the implications of this research extend into regulatory and operational domains. As the European Union moves toward monitoring and reporting non-CO₂ effects, accurate data becomes a prerequisite for compliance. Furthermore, if the hypothesis regarding flight path optimization is validated, we may see a fundamental shift in air traffic management, where climate impact is weighed alongside safety and efficiency in flight planning. This offers a potential “quick win” for the climate, allowing the aviation sector to reduce its warming impact significantly even before zero-emission propulsion technologies become widely available.

FAQ

What is the main goal of the DLR and TUI fly collaboration?
The primary goal is to investigate the climate impact of contrails generated by modern “lean-burn” aircraft engines and to validate flight path optimization strategies that could reduce aviation’s global warming footprint.

How is the data being collected?
A DLR Falcon 20E research aircraft follows TUI fly passenger flights (Boeing 737 MAX 8) at a distance of approximately 10 kilometers to measure the composition and evolution of the exhaust plume in real-time.

Why are contrails considered a climate problem?
Contrails can form cirrus clouds that trap heat in the Earth’s atmosphere. Scientific estimates suggest they may contribute as much or more to global warming than the CO₂ emissions from aviation.

What is the A4CLIMATE project?
A4CLIMATE is an EU-funded research initiative involving 17 partners from 9 countries. It aims to develop solutions to minimize aviation’s climate impact through advanced engines, sustainable fuels, and climate-optimized flight routing.

Sources: TUI Group

Bell 505 Surpasses 700 Flight Hours on Sustainable Aviation Fuel

We are witnessing a pivotal shift in the rotorcraft industry as manufacturers move from theoretical demonstrations to practical, sustained applications of green technology. On November 24, 2025, during the European Rotors 2025 trade show in Cologne, Germany, Bell Textron Inc. announced a significant achievement in this domain. A dedicated Bell 505 helicopter has successfully surpassed 700 flight hours using blended Sustainable Aviation Fuel (SAF). This milestone marks a transition from short-term testing to long-term operational validation.

The flight hours were accumulated at the Bell Training Academy in Fort Worth, Texas. By utilizing a training aircraft for this initiative, Bell has demonstrated the viability of SAF in high-volume, daily operations. This is not merely a proof of concept, it is a stress test of the fuel’s reliability under the rigorous demands of pilot training. The initiative highlights the seamless integration of alternative fuels into existing platforms without disrupting standard operating procedures.

This achievement is the result of a strategic collaboration between Bell and Safran Helicopter Engines. It underscores a shared commitment to reducing the carbon footprint of vertical lift operations. As the aviation sector faces increasing pressure to meet global sustainability targets, data-driven milestones like this provide the necessary evidence to encourage broader adoption of SAF among operators and regulatory bodies.

Operational Reliability and Technical Specifications

The aircraft at the center of this milestone is the Bell 505 Jet Ranger X, a short light single-engine helicopter known for its versatility in corporate, public safety, and training missions. Powered by the Safran Arrius 2R engine, the aircraft utilized a specific type of fuel known as “blended SAF.” This mixture typically combines 30 to 50 percent pure sustainable fuel with conventional Jet A fuel. The accumulation of over 700 flight hours confirms that the engine and airframe can operate consistently on this blend without requiring mechanical modifications.

One of the most critical aspects of this program is the demonstration of “drop-in” capability. In the context of aviation, a drop-in fuel is one that can be substituted for conventional jet fuel within existing infrastructure and engines. The Safran Arrius 2R is currently certified to operate on up to a 50 percent SAF blend. By logging substantial hours at the Bell Training Academy, we see proof that operators can integrate these fuels into their current logistics chains without the need for expensive retrofits or specialized handling equipment.

The fuel for this initiative was supplied through partnerships with key industry providers, including Neste and Avfuel. These collaborations are essential for establishing a reliable supply chain, which remains one of the primary hurdles for widespread SAF adoption. The successful completion of these flight hours serves as a signal to the market that the hardware is ready, provided the fuel supply continues to scale to meet demand.

“Bell is proud to celebrate this next step in industry carbon reduction objectives. Working alongside Safran Helicopter Engines has given us the cutting-edge advantage of exploring opportunities in greener aviation practices.”, Robin Wendling, Managing Director of Europe, Bell.

Strategic Implications and Future Roadmap

This 700-hour milestone is part of a broader timeline of sustainability efforts by Bell and its parent company, Textron. It supports Textron’s “Achieve 2025” Sustainable Footprint goal, which targets a 20 percent reduction in greenhouse gas (GHG) emissions across the enterprise. Furthermore, it aligns with the general aviation industry’s commitment to achieving net-zero carbon emissions by 2050. We recognize that incremental steps, such as validating blended fuels, are necessary precursors to achieving these ambitious long-term targets.

While the current operations utilize a blend, the technology is rapidly advancing toward higher concentrations of sustainable components. In February 2023, Bell and Safran achieved the world’s first single-engine helicopter flight using 100 percent SAF with the Bell 505. The current 700-hour achievement complements that breakthrough by focusing on endurance and daily utility rather than maximum capability. Safran has indicated that its engines will soon be capable of operating on 100 percent drop-in SAF, which would significantly maximize emission reductions.

Commercial interest in the Bell 505 remains strong alongside these sustainability developments. At the same European Rotors 2025 event, German operator Heli Transair signed a purchase agreement for three additional Bell 505 aircraft. This suggests that the market is responding positively to the platform, viewing its compatibility with sustainable practices as a value-add rather than a compromise on performance or cost-efficiency.

“We are particularly pleased with these SAF flights in partnership with Bell. SAF is key towards more sustainable helicopter use… Very soon, our engines will be capable of 100% drop-in SAF, paving the way for wider use of this type of fuel.”, Jean-François Sauer, EVP Programs, Safran Helicopter Engines.

Conclusion

The accumulation of over 700 flight hours on blended SAF by the Bell 505 represents a tangible step forward for sustainable rotorcraft operations. It moves the industry discussion from theoretical possibilities to proven realities, demonstrating that eco-friendly fuels can support the rigorous demands of pilot training and daily flight operations. By validating the performance of the Safran Arrius 2R engine with drop-in fuels, Bell has reduced the perceived risk for operators looking to transition to greener alternatives.

Looking ahead, the focus will likely shift toward increasing the availability of SAF and certifying engines for 100 percent sustainable fuel use. As manufacturers like Bell and Safran continue to refine the technology, and as supply chains mature, we anticipate that SAF will become a standard component of aviation logistics, driving the sector closer to its net-zero aspirations.

FAQ

What is the significance of the 700-hour milestone?
This milestone proves that the Bell 505 can operate reliably on blended Sustainable Aviation Fuel (SAF) over a long period in a high-volume training environment, validating the fuel for daily use.

Does using SAF require changes to the helicopter engine?
No. The blended SAF used is considered a “drop-in” fuel, meaning it requires no modifications to the Safran Arrius 2R engine or the airframe.

What is the difference between this milestone and the 2023 SAF flight?
The February 2023 flight demonstrated the capability to fly on 100% SAF. The current milestone focuses on the endurance and operational reliability of using blended SAF over 700 accumulated flight hours.

Sources

Textron Investor Relations