FedEx Adds First Converted ATR 72-600 Freighter to Fleet

FedEx Acquires the World’s First Converted ATR 72-600 Freighter

In a significant move for the regional air cargo industry, FedEx Express has committed to purchasing the world’s first passenger-to-freighter (P2F) converted ATR 72-600 aircraft. The aircraft, originally designed for passenger service, has undergone a comprehensive conversion to meet the specific demands of freight logistics. This initiative, led by ACIA Aero Leasing and executed by Empire Aerospace, marks a strategic milestone for FedEx as it seeks to modernize its regional fleet amidst shifting market dynamics and growing e-commerce volumes.

Scheduled for delivery in December 2025, this aircraft represents FedEx’s first acquisition of a converted freighter since 2016 and its first converted ATR since 2011. The move underscores FedEx’s broader commitment to cost-efficiency, sustainability, and operational flexibility in its feeder network operations. As the largest operator of ATR freighters globally, FedEx’s adoption of this converted model could signal a wider industry shift toward P2F conversions as a viable alternative to new-build freighters.

With proprietary modifications including a large cargo door, reinforced flooring, and compatibility with standard Unit Load Devices (ULDs), the converted ATR 72-600 is tailored to the specific needs of FedEx’s regional network. This development not only enhances FedEx’s capacity but also extends the service life of existing aircraft, offering a sustainable and economical solution for short-haul cargo operations.

Technical Innovations in the ATR 72-600 Conversion

The conversion of the ATR 72-600 from a passenger aircraft to a freighter involves extensive structural and systems modifications. ACIA Aero Leasing launched this speculative program in 2024, with Empire Aerospace, a sister company of Empire Airlines, handling the physical transformation. The process, which takes between four to seven months, includes the installation of a 3.45×1.95 meter forward large cargo door, a rear flip door, and a reinforced cargo floor capable of supporting a 9.2-tonne payload.

Additional enhancements include the integration of vertical restraint nets for bulk cargo, lateral track systems for containerized freight, and Class E fireproofing for the cargo compartment. These features ensure the aircraft is compliant with regulatory requirements and optimized for FedEx’s high-frequency, short-haul operations. The aircraft is also designed to accommodate up to seven LD3 containers or five 88×108-inch pallets, aligning with industry-standard cargo handling systems.

One of the standout features of this conversion is its cold-weather capability. Modified engine bleed air systems allow for reliable performance in temperatures as low as -40°C, making the aircraft suitable for operations in extreme environments such as Alaska and Northern Canada. Updated avionics, including enhanced ground proximity warning systems and optimized weight-and-balance software, further tailor the aircraft for efficient cargo operations.

“FedEx’s selection of our converted 72-600LCD reflects their demand for next-generation regional freighters with enhanced capabilities.”, Mark Dunnachie, SVP Commercial, ACIA Aero Leasing

FedEx’s Strategic Fleet Modernization

FedEx’s decision to incorporate a converted ATR 72-600 into its fleet is part of a broader strategy to modernize and optimize its regional aircraft operations. The company currently operates the largest ATR freighter fleet in the world, consisting of 24 factory-built ATR 72-600Fs, 19 ATR 72-200s, and 16 ATR 42s. These aircraft are primarily used in feeder networks across North America and Europe, operated by regional partners such as Empire Airlines and ASL Airlines Ireland.

The converted ATR 72-600 will replace older ATR 72-200 models, which are less fuel-efficient and lack modern cargo capabilities. This transition supports FedEx’s ongoing efforts to align capacity with evolving demand patterns, particularly in the wake of the COVID-19 pandemic, which reshaped global logistics and accelerated the growth of e-commerce. The aircraft’s 900-nautical-mile range and ability to operate from short runways make it ideal for serving smaller markets that are not economically viable for larger jets.

Financially, the conversion offers significant advantages. Compared to new-build freighters, the converted ATR 72-600 costs approximately 60–70% less and extends the airframe’s service life by 15–20 years. With fuel consumption 40% lower per ton-mile than comparable regional jets, the aircraft provides an estimated $450,000 in annual fuel savings per unit, enhancing FedEx’s cost-efficiency and environmental sustainability.

The Growing Passenger-to-Freighter Market

The global market for passenger-to-freighter conversions is experiencing rapid growth, driven by increasing e-commerce demand and the retirement of aging aircraft. According to industry analysts, the P2F market is projected to reach $6.4 billion by 2032, growing at a compound annual growth rate of 11.1%. Regional turboprops like the ATR 72 are particularly well-suited for conversion due to their robust design, high-wing configuration, and operational versatility.

In North America, express carriers such as FedEx and UPS are leading the charge in fleet modernization through conversions. The ATR platform dominates the regional P2F segment, holding a 68% market share. Regulatory agencies like the FAA and EASA have also streamlined certification processes, reducing conversion timelines and making the process more cost-effective for operators.

ACIA Aero Leasing has emerged as a key player in this space, delivering multiple ATR freighters in under two years and initiating discussions with other global operators for additional conversions. The success of FedEx’s initiative could serve as a catalyst for broader adoption of ATR 72-600 conversions across the industry.

Operational Deployment and Network Impact

Once delivered, the converted ATR 72-600 is expected to be deployed in FedEx’s Memphis or Cologne hubs, serving high-density regional routes such as Memphis-Chicago or Cologne-Amsterdam. These routes benefit from the aircraft’s quick turnaround capabilities, enabled by the rear flip door and front cargo loading system, which reduce ground time to approximately 35 minutes.

The aircraft will also support peak season operations, providing additional capacity during periods of high demand without necessitating permanent fleet expansion. Secondary markets, which previously relied on truck transport, will gain access to faster air services, improving delivery times and customer satisfaction.

From an environmental perspective, the aircraft aligns with FedEx’s goal of achieving carbon neutrality by 2040. With 30% lower CO2 emissions compared to jet-powered freighters, the ATR 72-600 conversion contributes to the company’s broader sustainability objectives while maintaining operational efficiency.

Conclusion

FedEx’s acquisition of the world’s first converted ATR 72-600 freighter represents a forward-thinking approach to fleet management and regional logistics. By leveraging the cost and operational benefits of P2F conversions, FedEx is enhancing its agility in a rapidly evolving market while maintaining its leadership in regional cargo transport.

As the air cargo industry continues to adapt to new economic realities and environmental imperatives, FedEx’s strategic investment in converted aircraft could pave the way for broader adoption of similar solutions. The successful integration of this aircraft into FedEx’s network will be closely watched by industry stakeholders, potentially setting new standards for regional air freight operations.

FAQ

What is the ATR 72-600 conversion? It is a passenger aircraft modified to carry freight, including structural changes like a large cargo door and reinforced flooring.

Why did FedEx choose a converted aircraft over a new one? Converted aircraft offer significant cost savings and faster deployment compared to new-build freighters.

Who performed the conversion for FedEx? The conversion was done by Empire Aerospace, under a program initiated by ACIA Aero Leasing.

When will the aircraft be delivered? The converted ATR 72-600 is expected to be delivered by December 2025.

How does this fit into FedEx’s sustainability goals? The aircraft emits 30% less CO2 than comparable jets, supporting FedEx’s goal of carbon neutrality by 2040.

Sources

FreightWaves, ACIA Aero Leasing, ATR Aircraft, IATA