MRO & Manufacturing
IAI Completes First Boeing 777-300ER Passenger to Freighter Conversion
Israel Aerospace Industries achieves first Boeing 777-300ER passenger-to-freighter conversion with dual FAA and CAAI certification, boosting cargo capacity and efficiency.
Israel Aerospace Industries (IAI) has made a historic leap in aviation by completing the world’s first Boeing 777-300ER passenger-to-freighter (P2F) conversion. This achievement, marked by dual certification from the US Federal Aviation Administration (FAA) and the Civil Aviation Authority of Israel (CAAI), positions IAI as a global leader in large-scale aircraft conversions. The converted aircraft, the B777-300ERSF, nicknamed “The Big Twin”, boasts a payload capacity of 100 tonnes, addressing the rising demand for high-capacity freighters amid global e-commerce expansion and supply chain shifts.
The significance of this milestone extends beyond technical prowess. It offers Airlines a cost-effective alternative to purchasing new cargo aircraft and creates new opportunities for fleet modernization. As the air cargo industry faces mounting pressures from e-commerce growth and the retirement of older freighters, IAI’s achievement signals a pivotal shift in how airlines and lessors can adapt to evolving logistics needs.
This article explores the historical context, technical challenges, market dynamics, and strategic implications of IAI’s Boeing 777 conversion program, drawing on industry data, expert insights, and official statements to provide a thorough, neutral analysis.
Israel Aerospace Industries’ journey to the forefront of aircraft conversions began in the 1960s, catalyzed by international defense embargos. These restrictions forced Israel to develop its own aerospace manufacturing capabilities, resulting in indigenous fighter aircraft like the IAI Nesher and Kfir. By the 1980s, IAI’s Bedek division had evolved into a major aircraft overhaul operation, employing thousands and developing an expertise that would later underpin its P2F conversion programs.
The company’s initial foray into P2F conversions started with Boeing 747s in the 1980s, laying the groundwork for decades of innovation. IAI’s diversification into radar, missile, and unmanned aerial vehicle technologies further expanded its engineering capabilities, enabling it to tackle complex projects like the 777-300ER conversion.
Over the years, IAI’s experience with ambitious projects, including the canceled Lavi fighter program, generated advanced technologies and a culture of adaptability. This background proved crucial as the company transitioned from maintenance and overhaul to pioneering large-scale aircraft conversions.
IAI’s conversion of the Boeing 777-300ER to a freighter is a first in aviation history. The milestone was reached in September 2025 when the company received Supplemental Type Certificates from both the FAA and CAAI, validating the aircraft for commercial cargo operations. This dual certification not only attests to the technical rigor of IAI’s program but also establishes its international credibility.
Boaz Levy, President and CEO of IAI, highlighted the significance of this achievement, noting that it demonstrates the company’s technological, engineering, and operational expertise. The B777-300ERSF, or “The Big Twin,” stands out as one of the world’s largest cargo aircraft, offering a unique blend of payload capacity, volume, and operational efficiency. The conversion program, spanning over 45 years and including more than 250 successful conversions across various aircraft types, builds on IAI’s extensive track record. The project involved complex engineering, from structural modifications to rigorous testing, underscoring the company’s position as a pioneer in the field.
“IAI is a global leader in passenger-to freighter aircraft conversions, standing at the forefront of aeronautical technology and building on its extensive capabilities as Israel’s largest aerospace company.”
, Boaz Levy, President and CEO of IAI
The B777-300ERSF offers a maximum payload of 100 tonnes, positioning it among the largest freighters globally. Compared to the Boeing 777-200F production freighter, it provides a 25% increase in volume while maintaining the same ground operation footprint. This expanded capacity is particularly advantageous for handling diverse cargo, from e-commerce parcels to oversized freight.
Fuel efficiency is a key differentiator: the B777-300ERSF consumes 21% less fuel per tonne than the Boeing 747-400 freighter, translating into lower operational costs and reduced environmental impact. These improvements align with industry trends toward sustainability and cost efficiency.
The conversion process is a complex engineering feat involving major structural modifications, such as installing a new cargo door, reinforcing the fuselage, and replacing the floor structure. The program typically requires more than 200 personnel and approximately 39 months from concept to certification, reflecting the technical challenges inherent in such large-scale conversions.
The global P2F conversion market is experiencing robust growth, driven by e-commerce expansion and shifting logistics patterns. Market research projects the freighter conversions market to reach over $1.6 billion by 2034, with a compound annual growth rate of 12.55%. The broader P2F market is expected to exceed $6.4 billion by 2032, reflecting sustained demand for cost-effective cargo capacity.
E-commerce is a primary catalyst for this surge. According to Boeing, online platforms now ship more than 10,000 tonnes of goods daily, equivalent to the capacity of 100 Boeing 777 freighters. Global e-commerce revenues are projected to surpass $8 trillion by 2026, further fueling demand for high-capacity, efficient cargo aircraft.
Conversion programs offer airlines a compelling value proposition: the cost of converting a Boeing 777 is estimated to be about 20% lower than purchasing a new Cargo-Aircraft. This cost advantage, combined with operational commonality with existing fleets, makes conversions an attractive option for airlines and lessors seeking to expand or modernize their cargo operations. “The volume capabilities and greater cost efficiencies of the 777-300ERSF will give us a competitive advantage in the market.”
, Helen Chen, CEO of Fly Meta
IAI’s first-mover advantage is notable, but competition is intensifying. Mammoth Freighters and Kansas Modification Center are developing their own Boeing 777 conversion programs, targeting both the 777-200LR and 777-300ER variants. Mammoth has secured 35 firm Orders and is advancing its prototype conversions, while KMC is exploring international expansion.
Supply constraints, particularly the limited availability of suitable 777-300ER feedstock, pose challenges for all providers. Many lessors are extending leases on existing fleets, limiting the pool of aircraft available for conversion. This scarcity may benefit established players like IAI, who have already secured significant commitments.
The competitive dynamics are further shaped by airlines’ need for operational commonality and cost efficiency. Converted 777s offer over 95% parts commonality with existing fleets, reducing training and maintenance costs, a key advantage in a market where efficiency is paramount.
Achieving dual certification from the FAA and CAAI required IAI to meet stringent regulatory standards. The certification process involved comprehensive evaluation of structural modifications, safety systems, and operational procedures. This level of scrutiny is comparable to that required for new aircraft production.
Regulatory harmonization enables operators to deploy converted aircraft across multiple jurisdictions without additional certification hurdles. This streamlines operations for global cargo carriers and enhances the commercial viability of conversion programs.
IAI’s thorough approach, including collaboration with regulatory authorities and extensive testing, ensures that the B777-300ERSF meets the same safety and performance standards as factory-built freighters.
AerCap, one of the world’s largest aircraft lessors, is the launch customer for IAI’s conversion program, with a firm order for 20 aircraft and options for ten more. Kalitta Air, a major US cargo airline, is the first operator, providing operational validation for the converted freighter. Additional customers, such as Fly Meta and Japan Airlines (via a codeshare with Kalitta Air), have also committed to the program. Emirates SkyCargo has expressed interest, though technical delays have been noted. These early adopters are critical in demonstrating the aircraft’s performance and building market confidence.
The converted 777’s ability to carry more cargo than the factory-built 777F and 747-400BCF, combined with its fuel efficiency, offers a compelling value proposition for operators seeking to modernize their fleets.
“Everyone thinks converting an aircraft from passenger to freighter is a simple process, but it involves similar principles and regulatory requirements that you would face when producing a factory new build aircraft.”
, Richard Greener, former SVP at GECAS Cargo
IAI’s successful conversion and certification of the Boeing 777-300ERSF marks a pivotal advancement in the air cargo industry. The aircraft’s combination of payload capacity, fuel efficiency, and operational commonality addresses the pressing needs of airlines and logistics providers amid a rapidly evolving global market.
As e-commerce continues to drive demand for efficient cargo solutions and older freighters retire, conversion programs like IAI’s are set to play an increasingly central role in fleet modernization. The success of the B777-300ERSF could accelerate industry adoption of P2F conversions, reshape aircraft lifecycle management, and set new standards for operational efficiency in air cargo.
What makes IAI’s Boeing 777-300ERSF conversion unique? Who are the launch customers for the converted 777-300ERSF? How does the converted 777-300ERSF compare to factory-built freighters? What are the main challenges facing the conversion program?
IAI’s Pioneering Boeing 777 Freighter Conversion: A Comprehensive Analysis of the Aviation Industry’s Latest Breakthrough
Historical Context and Company Background
The Historic Boeing 777 Conversion Achievement
Technical Specifications and Operational Capabilities
Market Context and Growing Demand for Freighter Conversions
Competition, Certification, and Strategic Implications
Competitive Landscape and Alternative Programs
Certification and Regulatory Framework
Launch Customers and Market Adoption
Conclusion
FAQ
It is the world’s first passenger-to-freighter conversion of the Boeing 777-300ER, offering a 100-tonne payload and 21% better fuel efficiency than the 747-400F. Dual certification from the FAA and CAAI sets a new industry benchmark.
AerCap is the launch customer with a firm order for 20 aircraft, and Kalitta Air is the first operator. Other customers include Fly Meta and Japan Airlines (via a partnership with Kalitta Air).
It offers more cargo volume than the 777F and 747-400BCF, with significant fuel savings and operational commonality with existing 777 fleets, making it a cost-effective and efficient alternative.
Limited availability of suitable aircraft for conversion, technical complexity, and competition from other conversion programs are key challenges. Delays and market acceptance risks also require careful management.
Photo Credit: IAI
MRO & Manufacturing
Bombardier Acquires Velocity Maintenance Solutions to Expand US Service Network
Bombardier acquires Velocity Maintenance Solutions, adding a Delaware facility and mobile repair units to enhance its U.S. aftermarket services.
On February 9, 2026, Bombardier announced the acquisition of Velocity Maintenance Solutions, a specialized provider of maintenance, repair, and overhaul (MRO) services based in Wilmington, Delaware. The transaction, executed through Bombardier’s U.S. subsidiary Learjet Inc., represents a strategic expansion of the manufacturer’s aftermarket footprint in the high-traffic Northeast corridor.
The acquisition provides Bombardier with immediate access to a 35,000-square-foot facility at New Castle Airport (ILG) and a fleet of mobile repair units designed for rapid response. While financial terms of the deal remain confidential, the move aligns with the company’s stated objective to grow its services revenue and secure a stronger domestic presence in the United States.
According to the company’s official statement, the acquisition is designed to bolster support for Bombardier’s growing fleet of business jets, including the ultra-long-range Global 8000. By integrating Velocity Maintenance Solutions, Bombardier aims to capture more of the lifecycle maintenance market, a sector that offers stable margins compared to the cyclical nature of aircraft sales.
The deal includes significant physical and operational assets that will be integrated into Bombardier’s service network:
Paul Sislian, Executive Vice President of Bombardier Aftermarket Services, highlighted the cultural fit between the two organizations in the press release.
“Velocity Maintenance Solutions’ capabilities and customer-focused culture make it an excellent fit for Bombardier… This acquisition is part of our commitment to continually elevate our service standards.”
Velocity Maintenance Solutions has established itself as an agile player in the MRO space since its emergence around 2021. As an FAA Part 145 Repair Station, the company is authorized to perform scheduled maintenance, structural repairs, and avionics upgrades.
Prior to the acquisition, Velocity serviced a diverse range of aircraft, including models from Embraer, Dassault Falcon, Gulfstream, and Textron, in addition to Bombardier jets. The facility is known for its 24/7 emergency support capabilities, a critical service for business jet operators requiring immediate dispatch reliability.
This acquisition arrives during a complex period for the aerospace industry, characterized by both consolidation and geopolitical friction. By executing the purchase through Learjet Inc., a heritage U.S. brand based in Wichita, Kansas, Bombardier reinforces its status as a significant U.S. employer. This distinction is increasingly vital as the company navigates trade tensions, including recent tariff threats from the U.S. administration regarding Canadian aerospace products.
Expanding physical infrastructure within the United States serves a dual purpose: it insulates the company’s service supply chain from potential cross-border friction and strengthens its eligibility for U.S. defense contracts. Furthermore, in an industry facing a chronic shortage of skilled labor, acquiring a “turnkey” operation with a certified workforce allows Bombardier to bypass the long lead times associated with recruiting and training new technicians. The location in Wilmington also places Bombardier in direct competition with other major service providers at New Castle Airport, including a Dassault Falcon service center, signaling an aggressive push to dominate the Northeast service market.
The acquisition was made by Learjet Inc., a U.S. subsidiary of Bombardier.
The existing team of technicians and support staff at Velocity Maintenance Solutions will be retained and integrated into Bombardier’s workforce.
While the press release emphasizes support for Bombardier’s fleet, Velocity has historically serviced various manufacturers. OEMs often honor existing third-party contracts during transition periods, though the long-term focus typically shifts to the parent company’s products.
Bombardier Acquires Velocity Maintenance Solutions to Densify U.S. Service Network
Expanding the Aftermarket Ecosystem
Target Profile: Velocity Maintenance Solutions
AirPro News Analysis: Strategic and Political Context
Frequently Asked Questions
Who is the acquiring entity?
What happens to the current workforce?
Will Velocity continue to service non-Bombardier aircraft?
Sources
Photo Credit: Velocity Maintenance Solutions
MRO & Manufacturing
Satair and Joramco Extend 25-Year Partnership at MRO Middle East 2026
Satair and Joramco renew their 25-year supply agreement at MRO Middle East 2026, supporting Joramco’s maintenance operations and new contracts.
This article is based on an official press release from Satair and additional industry reporting regarding MRO Middle East 2026.
At the MRO Middle East 2026 exhibition in Dubai, Satair, an Airbus Services company, and Joramco (Jordan Aircraft Maintenance Limited) officially announced the renewal of their long-standing Consumables and Expendables Supply Agreement. The deal marks the continuation of a strategic partnership that has spanned more than a quarter of a century, reinforcing the critical role of integrated supply chains in the growing Middle Eastern aviation maintenance sector.
According to the announcement, the renewed agreement is designed to secure a consistent flow of essential spare parts for Joramco’s base maintenance operations in Amman, Jordan. By locking in this supply chain solution, Joramco aims to minimize “Aircraft on Ground” (AOG) risks and reduce the complexity of material management for its expanding customer base.
The partnership between Satair and Joramco is one of the most enduring in the region. For over 25 years, Satair has served as a primary provider of consumables and expendables, high-volume, low-cost parts essential for routine maintenance, to the Jordan-based MRO provider.
In the official release, the companies highlighted the operational benefits of the extension. The agreement allows Joramco to leverage Satair’s global distribution network, ensuring that parts are available precisely when needed. This “just-in-time” capability is vital for MROs (Maintenance, Repair, and Overhaul providers) striving to offer competitive turnaround times to airlines.
A primary focus of the renewal is the mitigation of supply chain disruptions. By outsourcing the management of consumables to Satair, Joramco can focus its internal resources on heavy maintenance and engineering tasks rather than logistics. The agreement reportedly covers a comprehensive range of Airbus and Boeing fleet requirements, aligning with Joramco’s diverse capabilities.
“This continued partnership with Satair ensures we have the right parts at the right time, allowing us to deliver superior turnaround times to our global customers.”
, Statement attributed to Joramco leadership regarding the renewal
The renewal comes amidst a flurry of activity at MRO Middle East 2026, where both companies have announced significant independent expansions. The event, held on February 4–5, 2026, has served as a platform for major industry shifts in the region. According to industry reporting from the event, Joramco has also secured a major five-year heavy maintenance agreement with the German leisure carrier Condor. This deal will see Joramco performing base maintenance on Condor’s entire Airbus fleet, including the A320ceo, A320neo, and A330neo. Additionally, Joramco celebrated the first graduates of its Structured On-the-Job Training (SOJT) program, a move aimed at addressing the global shortage of skilled aviation technicians.
Simultaneously, Satair has expanded its footprint in the sustainability sector. Reports from the event indicate Satair signed a Memorandum of Understanding (MoU) with GAMECO (Guangzhou Aircraft Maintenance Engineering Co.) to enter the Used Serviceable Material (USM) market, addressing the rising demand for cost-effective and sustainable parts solutions.
The renewal of the Satair-Joramco agreement highlights a critical trend in the post-2025 aviation landscape: the prioritization of supply chain resilience. In an era where global parts shortages have frequently grounded fleets, MRO providers are increasingly moving toward long-term, integrated agreements with major distributors rather than relying on spot-market purchasing.
Furthermore, the Middle East’s trajectory as a global MRO hub is evident in these announcements. Joramco’s ability to secure European contracts like the Condor deal, backed by a robust supply chain from Satair, suggests that regional players are successfully competing on a global scale by combining geographic advantages with high-grade logistical reliability.
Satair and Joramco Extend 25-Year Supply Chain Partnership at MRO Middle East 2026
Strengthening a Quarter-Century Alliance
Operational Efficiency and AOG Reduction
Broader Context: MRO Middle East 2026 Developments
AirPro News Analysis
Frequently Asked Questions
Sources
Photo Credit: Satair
MRO & Manufacturing
Joramco Renews Maintenance Agreement with mas Cargo Airline for 2026
Joramco extends its maintenance contract with Mexican cargo airline mas for heavy checks on Airbus A330 freighters throughout 2026 at its Amman facility.
This article is based on an official press release from Joramco.
Joramco, the Amman-based aircraft maintenance, repair, and overhaul (MRO) facility and engineering arm of Dubai Aerospace Enterprise (DAE), has officially announced the renewal of its maintenance agreement with mas (formerly MasAir), a prominent Mexican cargo airline. The agreement was finalized and signed during the MRO Middle East 2026 exhibition in Dubai, marking a continuation of the strategic partnership between the two entities.
Under the terms of the renewed contract, Joramco will perform heavy base maintenance checks on the mas fleet of Airbus A330 freighters. The work is scheduled to take place throughout 2026 at Joramco’s facility at Queen Alia International Airport in Amman, Jordan. This announcement underscores the MRO provider’s increasing traction in the global cargo sector and its ability to secure recurring business from international carriers outside its traditional regional stronghold.
According to the company’s announcement, the new deal focuses specifically on heavy base maintenance, often referred to as C-checks, for the carrier’s Airbus A330 fleet. These checks are critical for ensuring the continued airworthiness and operational reliability of the freighter aircraft, which are essential to mas’s global logistics network.
This renewal follows a successful initial collaboration established relatively recently. Joramco and mas first formalized their partnerships in October 2025 at the MRO Europe exhibition in London. That initial agreement covered maintenance checks that began in December 2025. The rapid renewal, signed just four months later, suggests a successful execution of the initial checks and a deepening of the business relationship.
In a statement regarding the renewal, Joramco’s leadership highlighted the significance of the repeat business.
“We are pleased to welcome more aircraft from mas at Joramco. This agreement reaffirms Joramco’s position as a trusted Global MRO provider of choice.”
, Adam Voss, CEO of Joramco
The agreement with mas aligns with Joramco’s broader strategy to expand its global footprint. By securing a renewal with a Latin American carrier, the Jordan-based MRO is demonstrating its competitiveness on a global scale, attracting airframes from the Americas to the Middle-East for heavy maintenance. The timing of this renewal is notable within the wider context of the MRO industry’s capacity constraints. In late 2025, Joramco inaugurated “Hangar 7,” a significant infrastructure expansion that reportedly increased its capacity to 22 parallel maintenance lines. This expansion appears to be paying dividends, allowing the facility to accommodate the “more aircraft” referenced by CEO Adam Voss.
Furthermore, the cargo market remains a demanding sector requiring high asset utilization. For a specialized Cargo-Aircraft airline like mas, which operates a modernizing fleet of Airbus A330 Passenger-to-Freighter (P2F) aircraft, securing reliable MRO slots is a strategic priority. The quick transition from an initial contract in late 2025 to a full-year renewal for 2026 indicates that Joramco has successfully met the technical and turnaround time requirements demanded by the cargo carrier.
Joramco: A subsidiary of Dubai Aerospace Enterprise (DAE), Joramco has operated for over 60 years. Based in Amman, Jordan, it provides airframe maintenance, repair, and overhaul services for Airbus, Boeing, and Embraer aircraft.
mas: Headquartered in Mexico City, mas (formerly MasAir) is a specialized cargo airline operating scheduled and charter freight services across the Americas, Europe, and Asia. The airline has been actively expanding its capacity with Airbus A330 freighters to support its international network.
Sources:
Joramco Extends Maintenance Partnership with mas Cargo Airline for 2026
Scope of the Renewed Agreement
Strategic Context and Capacity Expansion
AirPro News Analysis
About the Companies
Photo Credit: Joramco
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