Aircraft Orders & Deliveries
AerCap Delivers First Boeing 777-300ERSF Converted Freighters to Kalitta Air
AerCap delivers first Boeing 777-300ERSF converted freighters to Kalitta Air, offering 100-ton payload and improved fuel efficiency for sustainable air cargo.
AerCap Holdings N.V., the world’s largest aircraft leasing company, has achieved a significant milestone in aviation history by delivering the first two Boeing 777-300ERSF passenger-to-freighter converted aircraft to Kalitta Air on September 12 and 13, 2025. This delivery represents the culmination of a multi-year development program that has transformed retired passenger aircraft into state-of-the-art cargo planes capable of carrying 100 tonnes of payload. The achievement marks not only a technological breakthrough in aircraft conversion but also signals a new era in air cargo transportation, as the aviation industry seeks more efficient and environmentally sustainable solutions to meet growing global freight demand.
With certification from both the Civil Aviation Authority of Israel and the Federal Aviation Administration, these converted aircraft offer airlines a cost-effective alternative to new-build freighters while providing superior operational efficiency compared to aging 747 cargo fleets. The 777-300ERSF program is seen as a pivotal response to the evolving demands of the global logistics ecosystem, emphasizing operational flexibility, sustainability, and financial prudence.
The delivery not only benefits Kalitta Air, the launch operator and a major player in the global cargo market, but also sets a precedent for future passenger-to-freighter conversion projects. The program’s success is expected to influence cargo fleet renewal strategies and drive innovation in the air freight industry.
The Boeing 777-300ERSF conversion program is the result of a sophisticated collaboration between AerCap and Israel Aerospace Industries (IAI), a company with more than 40 years of experience in passenger-to-freighter conversions. AerCap, headquartered in Dublin, serves approximately 300 customers worldwide and manages a fleet of over 1,700 commercial aircraft. The company’s growth and market dominance have been fueled by strategic acquisitions, including the $7.6 billion purchase of International Lease Finance Corporation in 2014 and the $30 billion acquisition of GE Capital Aviation Services in 2021.
The conversion program’s origins trace back to 2020, when Kalitta Air became the launch operator, positioning itself at the forefront of cargo aviation innovation. Kalitta Air, founded in 1967 by Conrad “Connie” Kalitta, has evolved into a global air cargo company operating more than 25 aircraft, including Boeing 777 and 747-400 freighters. The decision to partner with AerCap on the 777-300ERSF program was driven by the strategic need to replace an aging 747 freighter fleet with more efficient twin-engine aircraft.
The program’s development required the combined efforts of over 200 people and took approximately 39 months from concept to certification. IAI’s extensive experience in converting aircraft, including hundreds of 737, 747, and 767 models, provided a solid foundation for the project. The company’s global network of conversion facilities spans five continents, ensuring the infrastructure necessary to meet rising demand for converted freighters.
The 777-300ERSF conversion is a remarkable feat of engineering, transforming a passenger airliner into one of the most capable cargo planes in operation today. The converted aircraft boasts a 100-metric-ton payload capacity and 811 cubic meters of cargo volume, offering significant operational advantages over existing widebody freighters. The “ERSF” designation, Extended Range Special Freighter, highlights the aircraft’s enhanced capabilities for long-haul cargo operations.
The conversion process involves extensive modification of the aircraft’s structure and systems. Major structural changes include cutting the fuselage to install a new cargo door, replacing the composite floor with reinforced aluminum, and installing a rigid barrier to withstand forces up to 9 g’s. The passenger deck is transformed into a full cargo compartment, and a supernumeraries compartment is created for crew quarters behind the pilots’ cabin. IAI employs sophisticated engineering methods such as finite element modeling and rigorous ground and flight tests to ensure structural integrity after modifications. The converted aircraft maintains over 95% commonality with the standard 777 passenger fleet, simplifying maintenance, training, and operational integration for airlines. Its twin-engine configuration reduces fuel consumption, maintenance costs, and improves airport accessibility compared to older four-engine alternatives.
“This aircraft will give us greater range and payload capability to meet growing demand in the global cargo market.” — Connie Kalitta, CEO of Kalitta Air
The certification of the 777-300ERSF is a watershed moment in aircraft conversion technology. IAI secured the first-ever Supplemental Type Certificate for a Boeing 777 conversion from both the Civil Aviation Authority of Israel and the U.S. Federal Aviation Administration. The process involved extensive ground and flight testing, and collaboration with additional authorities such as the European Union Aviation Safety Agency to ensure global operational acceptance.
The 100-tonne payload certification positions the 777-300ERSF among the most capable cargo aircraft in operation. The dual certification validates the aircraft’s structural integrity and operational safety under the full range of cargo operations. This achievement reflects years of dedicated effort and sets a new benchmark for passenger-to-freighter conversions.
Yaacov Berkovitz, Executive Vice President and General Manager of IAI’s Aviation Group, emphasized that this milestone “sets a new standard in air cargo, delivering a unique combination of high payload capacity, volume and operational efficiency.”
The 777-300ERSF enters a dynamic air cargo market characterized by strong demand and evolving capacity constraints. The global air cargo market was valued at $185.3 billion in 2023, with projected growth driven by e-commerce, global trade, and the need for time-sensitive deliveries. The converted 777-300ERSF provides compelling advantages in both cost and operational efficiency compared to new-build freighters and older cargo aircraft.
Industry analysis indicates that a converted 777-300ER, including conversion and maintenance, costs approximately $69.8 million, significantly less than a comparable new-build 777F. As more 777-300ER aircraft become available for conversion, especially with airlines accelerating retirements, the cost advantages are expected to increase. The aircraft’s 21% fuel burn improvement per ton compared to the 747-400F translates into lower emissions and reduced operating costs.
Boeing forecasts a 67% increase in the global freighter fleet by 2044, with passenger-to-freighter conversions representing a significant portion of new capacity. The 777-300ERSF’s operational and financial advantages position it strongly against both factory-built and competing converted freighters.
“The activity that currently contributes most to decarbonization is fleet renewal, and AerCap continues to play a leading role by investing in the most fuel-efficient new technology aircraft.” — AerCap Holdings N.V.
AerCap’s delivery of the first 777-300ERSF aircraft comes amid strong financial performance. The company reported record net income of $1,259 million for the second quarter of 2025, driven by robust demand for aviation assets and a 97% lease extension rate. The 777-300ERSF program represents a strategic diversification into the growing cargo conversion sector, with over 50 firm orders and options reported for the program. The conversion economics are attractive for both lessors and operators. With conversion costs around $30 million (excluding maintenance), total investment for a 777-300ERSF is substantially lower than for new-build alternatives. The program’s initial seven-aircraft order from Kalitta Air provides a foundation for further expansion, and its success is expected to generate additional orders from major leasing companies and cargo carriers worldwide.
The strong financial results and high retention rates demonstrate the essential nature of AerCap’s services and the growing importance of efficient, modern cargo aircraft in global logistics.
The 777-300ERSF program aligns with the aviation industry’s broader sustainability and decarbonization goals. The converted aircraft delivers up to 21% fuel burn improvement per ton compared to older four-engine freighters, directly reducing carbon dioxide emissions per kilogram of cargo transported. These environmental benefits support global efforts to minimize aviation’s impact on climate change.
IAI’s conversion process incorporates eco-friendly practices, including responsible material handling, waste minimization, and recycling of structural components. The aircraft’s twin-engine configuration also results in lower noise emissions, improving operational flexibility at noise-sensitive airports.
Fleet renewal through conversion programs is one of the most impactful activities contributing to aviation decarbonization. The 777-300ERSF program exemplifies how the industry can transform retired passenger aircraft into efficient, environmentally responsible cargo planes.
The delivery of the first 777-300ERSF occurs within a complex global air cargo market experiencing both opportunities and challenges. According to the International Air Transport Association, July 2025 saw a 5.5% increase in cargo tonne-kilometers compared to the previous year, with the Asia Pacific region leading growth. However, some analysts predict that air cargo volumes could flatten in 2025 as businesses adapt to changing supply chain dynamics and e-commerce growth stabilizes.
Capacity constraints due to the retirement of older aircraft, manufacturing delays for new freighters, and regulatory hurdles for conversion programs present both risks and opportunities. Early certification and delivery give the AerCap/IAI program a competitive edge, while competitors such as Mammoth Freighters and Kansas Modification Center pursue their own 777 conversion projects.
The competitive landscape underscores the strong market potential for 777 conversions, with the first-mover advantage likely to benefit AerCap and IAI as additional orders and partnerships are secured. “We are delighted to deliver the very first 777-300ERSF to our unwavering partner Kalitta Air, who have been with us shoulder to shoulder throughout this journey.” — Aengus Kelly, CEO of AerCap
The success of the 777-300ERSF program is rooted in strong strategic partnerships. AerCap, IAI, and Kalitta Air have collaborated closely throughout the development and certification process. Kalitta Air’s role as launch operator provides crucial operational validation, leveraging its experience with both 777 and 747 freighters.
The rapid transition from delivery to revenue service, scheduled for early October 2025, demonstrates operational readiness and confidence in the program. The partnership model established for the 777-300ERSF could serve as a template for future conversion initiatives, combining leasing, technical, and operational expertise to address market needs.
As additional aircraft are delivered to Kalitta Air and other customers, operational data will further validate the program’s benefits and support expansion into new markets.
The delivery of AerCap’s first Boeing 777-300ERSF converted freighters to Kalitta Air marks a transformative moment in aviation. It demonstrates the viability of large-scale passenger-to-freighter conversion programs and provides a cost-effective, environmentally responsible solution for cargo operators seeking to modernize their fleets.
The program’s success reflects the strength of strategic partnerships and the importance of innovation in addressing market and environmental challenges. With robust demand for converted freighters and a favorable regulatory framework established, the 777-300ERSF is poised to play a central role in the future of global air cargo.
What is the Boeing 777-300ERSF? Who is the launch operator for the 777-300ERSF? What are the environmental benefits of the 777-300ERSF? How does the 777-300ERSF compare cost-wise to new freighters? What is the future outlook for passenger-to-freighter conversions? Sources: PRNewswire, AerCap Holdings N.V., Israel Aerospace Industries, Kalitta Air
AerCap’s Historic Delivery of First Boeing 777-300ERSF Converted Freighters Marks Aviation Industry Milestone
Background and Program Development
Technical Specifications and Conversion Process
Certification Achievement and Regulatory Milestone
Market Positioning and Competitive Landscape
Financial Performance and Business Implications
Environmental and Sustainability Benefits
Industry Context and Market Dynamics
Strategic Partnerships and Operational Integration
Conclusion
FAQ
The 777-300ERSF is a passenger-to-freighter converted aircraft, offering a 100-tonne payload and improved fuel efficiency compared to older cargo aircraft.
Kalitta Air is the launch operator and has received the first two converted aircraft as part of a seven-aircraft order.
The aircraft delivers up to 21% fuel burn improvement per ton compared to older four-engine freighters, resulting in lower emissions and reduced environmental impact.
A converted 777-300ERSF is significantly less expensive than a new-build freighter, offering airlines a cost-effective alternative for fleet renewal.
Industry forecasts project strong demand for converted freighters, with programs like the 777-300ERSF expected to play a key role in meeting global cargo capacity needs.
Photo Credit: AerCap
Aircraft Orders & Deliveries
Qanot Sharq Receives First Airbus A321XLR in Central Asia
Qanot Sharq becomes Central Asia’s first operator of the Airbus A321XLR, expanding long-haul routes to North America and Asia from Tashkent.
This article is based on an official press release from Airbus and Qanot Sharq.
On December 19, 2025, Qanot Sharq, Uzbekistan’s first private airline, officially took delivery of its first Airbus A321XLR (Extra Long Range) aircraft. The delivery, facilitated through a lease agreement with Air Lease Corporation (ALC), marks a historic milestone for aviation in the region, as Qanot Sharq becomes the launch operator of the A321XLR in Central Asia and the Commonwealth of Independent States (CIS).
This aircraft is the first of four confirmed A321XLR units destined for the carrier. According to the official announcement, the airline intends to utilize the aircraft’s extended range to open new long-haul markets that were previously inaccessible to single-aisle jets, including planned services to North America and East Asia.
The newly delivered A321XLR is powered by CFM International LEAP-1A engines and features a two-class layout designed to balance capacity with passenger comfort on longer sectors. The aircraft accommodates a total of 190 passengers.
In addition to the seating configuration, the aircraft is fitted with Airbus’ “Airspace” cabin interior. Key features include customizable LED lighting, lower cabin altitude settings to reduce jet lag, and XL overhead bins that provide 60% more storage capacity compared to previous generation aircraft.
Nosir Abdugafarov, the owner of Qanot Sharq, emphasized the strategic importance of the delivery in a statement regarding the fleet expansion.
“The A321XLR’s exceptional range and efficiency will allow us to offer greater comfort and convenience while maintaining highly competitive operating economics.”
, Nosir Abdugafarov, Owner of Qanot Sharq
The introduction of the A321XLR allows Qanot Sharq to deploy a narrowbody aircraft on routes typically reserved for widebody jets. With a range of up to 4,700 nautical miles (8,700 km), the airline plans to connect Tashkent with destinations in Europe, Asia, and North America.
According to the airline’s strategic roadmap, the new fleet will support route expansion to Sanya (China) and Busan (South Korea). Furthermore, the airline has explicitly outlined plans to serve New York (JFK) via Budapest. While the A321XLR has impressive range, the distance between Tashkent and New York (approximately 5,500 nm) necessitates a technical stop. Budapest will serve as this intermediate point, potentially allowing the airline to tap into passenger demand between Central Europe and the United States, subject to regulatory approvals. AJ Abedin, Senior Vice President of Marketing at Air Lease Corporation, noted the geographical advantages available to the airline.
“Qanot Sharq is uniquely positioned to unlock the full potential of the A321XLR due to its strategic location in Uzbekistan, bridging Europe and Asia.”
, AJ Abedin, SVP Marketing, Air Lease Corporation
The delivery of the A321XLR signals a distinct shift in the competitive landscape of Uzbek aviation. Until now, long-haul flights from Tashkent,specifically to the United States,have been the exclusive domain of the state-owned flag carrier, Uzbekistan Airways, which utilizes Boeing 787 Dreamliners for non-stop service.
By adopting the A321XLR, Qanot Sharq appears to be pursuing a “long-haul low-cost” hybrid model. The A321XLR burns approximately 30% less fuel per seat than previous-generation aircraft, allowing the private carrier to operate long routes with significantly lower trip costs than its state-owned competitor. While the one-stop service via Budapest will result in a longer total travel time compared to Uzbekistan Airways’ direct flights, the lower operating costs could allow Qanot Sharq to offer more competitive fares, appealing to price-sensitive travelers and labor migrants.
Furthermore, the choice of Budapest as a stopover is strategic. If Qanot Sharq secures “Fifth Freedom” rights,which are currently a subject of regulatory negotiation,it could monetize the empty seats on the Budapest-New York sector, effectively competing in the transatlantic market while serving its primary base in Central Asia.
Sources: Airbus Press Release, Air Lease Corporation
Qanot Sharq Becomes First Central Asian Operator of Airbus A321XLR
Aircraft Configuration and Capabilities
Strategic Network Expansion
AirPro News Analysis: The Long-Haul Low-Cost Shift
Sources
Photo Credit: Airbus
Aircraft Orders & Deliveries
China Airlines Orders Five Additional Airbus A350-1000 Aircraft
China Airlines adds five Airbus A350-1000s to its fleet, enhancing capacity on transpacific and European routes with deliveries from 2026.
This article is based on an official press release from Airbus and additional industry data regarding fleet modernization.
China Airlines (CAL) has officially signed a firm orders for five additional Airbus A350-1000 aircraft, signaling a continued commitment to modernizing its long-haul operations. Announced on December 18, 2025, this agreement increases the Taiwan-based carrier’s total backlog for the A350-1000 variant to 15 aircraft. The move is part of a broader strategy to replace aging widebody jets and enhance capacity on high-density routes connecting Asia with North America and Europe.
According to the official statement released by Airbus, these new aircraft will join the airline’s existing fleet of 15 A350-900s. The decision to expand the A350-1000 order book underscores the operator’s reliance on the A350 family’s commonality, which allows for streamlined pilot training and maintenance procedures. Deliveries for the newly ordered jets are scheduled to commence in 2026 and continue through 2029.
The deal also highlights the competitive landscape of widebody aviation in the Asia-Pacific region. By securing these additional units, China Airlines aims to deploy its flagship product on slot-constrained routes where maximizing passenger count per movement is critical. The aircraft will be powered by Rolls-Royce Trent XWB-97 engines, known for their efficiency in long-range operations.
China Airlines plans to utilize the A350-1000 primarily for its most prestigious long-haul markets. Industry reports indicate that the aircraft will be deployed on key transpacific routes to New York (JFK), Los Angeles (LAX), Seattle (SEA), and Ontario, California (ONT), as well as European hubs like London Heathrow (LHR). The A350-1000 offers significantly higher capacity than the -900 variant, making it a strategic asset for airports with limited landing slots.
Coinciding with these deliveries, the airline is preparing to unveil a major upgrade to its onboard product. Sources familiar with the carrier’s fleet planning suggest a new cabin design will debut in 2027. This retrofit is expected to feature business class suites with closing doors, 4K entertainment screens, and wireless charging capabilities, aiming to rival premium competitors such as Singapore Airlines and Cathay Pacific.
The interior aesthetic will likely continue the carrier’s “Oriental aesthetics” theme, utilizing persimmon wood-grain finishes and mood lighting to evoke a boutique hotel atmosphere. While the current A350-900 seats 306 passengers, the larger -1000 variant is projected to accommodate between 350 and 400 passengers, providing a substantial boost in premium economy and economy seat inventory.
Both China Airlines and Airbus executives emphasized the efficiency and passenger comfort benefits of the A350-1000. In the official press release, Kao Shing-Hwang, Chairman of China Airlines, noted the alignment of this order with the carrier’s sustainability and service goals. “Expanding our A350-1000 fleet marks another important step in our long-term growth strategy. The A350’s exceptional efficiency and passenger comfort align with our goals to modernize our fleet, enhance long-haul competitiveness, and deliver an elevated travel experience to our customers.”
Kao Shing-Hwang, Chairman of China Airlines
Benoit de Saint-Exupéry, Airbus EVP Sales, added that the repeat order validates the aircraft’s performance in the heavy widebody segment.
“This follow-on order is a strong vote of confidence in the A350-1000 as the right aircraft for China Airlines’ future network ambitions. Its next-generation efficiency, range, and cabin comfort brings even greater value to the airline and its passengers.”
Benoit de Saint-Exupéry, Airbus Sales
This order reinforces a “split fleet” procurement strategy that has become increasingly common among major global carriers. While China Airlines has committed to the Boeing 777X for specific high-volume trunk routes and the 787 Dreamliner for regional replacement, the expansion of the A350-1000 fleet secures Airbus’s position as the backbone of the airline’s medium-to-large widebody operations.
From a financial perspective, based on 2025 list prices of approximately $366.5 million per unit, the deal holds a theoretical face value of roughly $1.83 billion, though actual acquisition costs are typically 40-50% lower after standard industry discounts. Environmentally, the shift is significant; the A350-1000 offers a 25% reduction in fuel burn compared to the previous generation aircraft it replaces, such as the Boeing 747-400 freighters and older passenger jets. This efficiency gain is a critical component of the airline’s roadmap to achieving Net Zero carbon emissions by 2050.
China Airlines Bolsters Long-Haul Capacity with Additional A350-1000 Order
Strategic Deployment and Cabin Innovation
Next-Generation Passenger Experience
Executive Commentary
AirPro News Analysis
Sources
Photo Credit: Airbus
Aircraft Orders & Deliveries
Natilus Launches India Subsidiary and Secures SpiceJet Aircraft Order
Natilus expands into India with a Mumbai subsidiary and a 100-aircraft order from SpiceJet for its Horizon blended-wing body plane.
This article is based on an official press release from Natilus.
Natilus, a U.S.-based aerospace manufacturers specializing in Blended-Wing Body (BWB) Commercial-Aircraft, has officially announced its expansion into the Indian aviation market. According to the company’s press release, the move includes the debut of a new subsidiary, Natilus India, headquartered in Mumbai. This strategic expansion is designed to address the growing demand in one of the world’s fastest-developing aviation sectors.
Coinciding with the launch of the new subsidiary, Natilus announced a significant commercial agreement with Indian low-cost carrier SpiceJet. The Airlines has committed to purchasing 100 units of Natilus’s “Horizon” passenger aircraft. The company noted that this transaction is subject to the successful Certification of the aircraft, which is currently in the development phase.
The establishment of Natilus India represents a direct effort to localize operations within a key global market. In its announcement, Natilus confirmed the appointment of Ravi Bhatia as the Regional Director for the new subsidiary. Bhatia’s role will focus on overseeing in-country operations, managing regulatory engagement with Indian aviation authorities, and fostering industrial Partnerships.
The company stated that this move aligns with India’s “Make in India” initiative. By establishing a physical presence in Mumbai, Natilus aims to source components and engineering services locally, integrating Indian manufacturing capabilities into its global Supply-Chain.
The purchase order from SpiceJet marks a pivotal moment for the “Horizon” program. If completed, this deal would position SpiceJet as an early adopter of BWB technology in the region. The “Horizon” is Natilus’s flagship passenger model, designed to seat between 200 and 240 passengers.
According to performance data released by Natilus, the aircraft is engineered to replace traditional narrowbody fleets, such as the Boeing 737 and Airbus A320 families, with a range of approximately 3,500 nautical miles.
Natilus is distinguishing itself from traditional aerospace manufacturers through its focus on the Blended-Wing Body design. Unlike the conventional “tube-and-wing” architecture, the BWB design integrates the fuselage and wings into a single lifting body. In its official communications, Natilus claims this aerodynamic shift offers significant efficiency gains:
While the announcement signals strong momentum for Natilus, the timeline and regulatory hurdles remain significant factors. The “Horizon” aircraft is expected to enter service in the early 2030s, meaning the realization of the SpiceJet order is likely a decade away. Furthermore, the deal is explicitly “subject to certification.” Natilus is currently pursuing FAA Part 25 certification in the United States, which must be achieved before the Directorate General of Civil Aviation (DGCA) in India can validate the aircraft for local operations.
For SpiceJet, this commitment appears to be a long-term strategic bet on efficiency. The airline, which has faced recent financial volatility, is looking to future-proof its fleet against rising fuel costs. By locking in orders for an aircraft that promises 50% lower operating costs, the carrier is signaling a focus on long-term profitability despite current market challenges.
The move also places Natilus in direct competition with other BWB developers, such as JetZero, which has secured backing from major U.S. carriers. However, by establishing a dedicated subsidiary in India, Natilus is attempting to secure a “first-mover” advantage in the Asian market, which industry forecasts suggest will require over 2,200 new aircraft by 2040.
Natilus Launches India Subsidiary; Secures Commitment for 100 Aircraft from SpiceJet
Strategic Expansion and Leadership
The SpiceJet Commitment
Technological Innovation: The Blended-Wing Body
AirPro News Analysis: Market Context and Risks
Sources
Photo Credit: Natilus
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