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Montana Renewables Launches MaxSAF to Expand Sustainable Aviation Fuel Access

Montana Renewables introduces MaxSAF, a certified blended sustainable aviation fuel, increasing regional availability and planning major capacity expansion.

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Photo: Calumet, Inc.

Montana Renewables Fuels a Greener Sky with MaxSAF™ Launch

The Airlines industry is at a critical juncture, facing mounting pressure to decarbonize and mitigate its environmental impact. In this landscape, the development and adoption of Sustainable Aviation Fuel (SAF) represent one of the most promising pathways toward a lower-carbon future for air travel. On October 27, 2025, Montana Renewables (MRL), a subsidiary of Calumet, Inc., took a significant step in this direction by announcing the launch of MaxSAF™, a blended sustainable aviation fuel. This move not only marks a milestone for the company but also signals a broader shift in the accessibility and distribution of cleaner fuels within the North-America market.

The introduction of MaxSAF™ is more than just a new product release; it’s a strategic advancement in the SAF supply chain. By commissioning onsite blending and shipping facilities at its Great Falls, Montana, location, MRL is now capable of delivering a ready-to-use, “drop-in” fuel directly to regional markets. This development is poised to expand SAF availability beyond major international airports, making it more accessible to a wider range of aviation operators. As one of only three commercial-scale SAF producers in North America, Montana Renewables’ initiative underscores the growing momentum and industrial maturity of the renewable fuels sector.

This launch arrives at a time of significant global interest and investment in SAF. Driven by ambitious airline commitments to achieve net-zero emissions, coupled with supportive government policies like the Inflation Reduction Act (IRA), the demand for SAF is on a steep upward trajectory. However, the industry faces considerable challenges, including scaling production to meet this demand, managing costs, and securing sustainable feedstocks. The launch of MaxSAF™ by a key domestic producer represents a tangible step forward in addressing these challenges, particularly in simplifying logistics and improving regional fuel availability.

A Closer Look at MaxSAF™ and its Market Impact

Montana Renewables’ new offering, MaxSAF™, is a nominal 50/50 blend of sustainable aviation fuel and conventional jet fuel. This blended product is certified under both ASTM D7566 and ASTM D1655 specifications, ensuring it is fully compatible with existing aircraft and fueling infrastructure. This “drop-in” capability is crucial for seamless adoption by airlines and other aviation operators, as it requires no modifications to their current equipment or procedures. The ability to produce a pre-blended, certified fuel directly at the production site streamlines the supply chain, eliminating logistical hurdles and costs associated with blending at downstream terminals.

The initial distribution of MaxSAF™ will be managed by AEG Fuels, a global fuel logistics company. The first shipments are targeted for aviation hubs in Montana, Washington, and Oregon, demonstrating a clear strategy to serve regional markets directly from the Great Falls facility. This approach is a significant departure from the conventional model, where SAF is often concentrated at major coastal Airports. By opening up local and regional service, MRL is democratizing access to sustainable fuels and enabling smaller operators to contribute to the industry’s environmental, social, and governance (ESG) goals.

The environmental benefits are a core component of the MaxSAF™ value proposition. SAF is known to significantly reduce lifecycle greenhouse gas emissions compared to its fossil-based counterpart. Furthermore, it can improve local air quality by reducing particulate matter emissions. The feedstocks used by Montana Renewables, which include tallow, distillers corn oil, canola oil, used cooking oil, and camelina oil sourced from the Pacific Northwest, also support a circular economy, creating value from agricultural byproducts and waste streams.

“AEG Fuels is honored to collaborate with Montana Renewables on this landmark SAF inaugural blend. Together, we’re demonstrating how strategic partnerships can accelerate the transition to sustainable aviation and deliver real value to operators across our fueling network.” – Landon Larson, Vice President, Supply NA at AEG Fuels.

Strategic Expansion and Future Production

The launch of the blended MaxSAF™ product is a key part of a much larger strategic vision for Montana Renewables. The company is on an ambitious path to become one of the largest SAF producers in the world. This expansion is supported by a conditional commitment for a $1.44 billion loan guarantee from the U.S. Department of Energy, aimed at funding the construction and enhancement of its biorefinery. The overarching “MaxSAF” initiative aims to increase the facility’s annual production capacity to 300 million gallons of SAF and 30 million gallons of renewable diesel.

In a significant development, Calumet announced in May 2025 an accelerated timeline for the first phase of this expansion. The company now expects to bring 120-150 million gallons per year of SAF capacity online by early 2026, much sooner than originally anticipated and at a fraction of the initial cost estimates. This acceleration is made possible by leveraging and enhancing existing assets and technology, demonstrating the company’s operational agility and commitment to rapidly scaling its output. This first phase alone will dramatically increase the domestic supply of SAF.

This rapid scaling is critical in the context of the broader market. While the growth projections for SAF are impressive, current production levels meet only a small fraction of global jet fuel demand. The U.S. government’s Sustainable Aviation Fuel Grand Challenge has set a goal of producing 3 billion gallons of SAF annually by 2030. Montana Renewables’ expansion plans are directly aligned with these national objectives, positioning the company as a key contributor to achieving a more sustainable aviation sector. The modular design of their expansion allows for a phased approach, bringing significant new capacity online in stages to meet evolving market demand.

Conclusion: Charting a Course for Sustainable Skies

The Launch of MaxSAF™ by Montana Renewables is a noteworthy event in the ongoing journey to decarbonize aviation. It represents a practical and immediate solution that enhances the accessibility of sustainable fuels, particularly for regional markets that have been underserved. By offering a pre-blended, certified, and drop-in ready product, MRL is lowering the barriers to adoption and simplifying the complex logistics that have historically challenged the SAF market. This move, backed by a robust expansion strategy and significant government support, solidifies the company’s role as a leader in the North American renewable fuels landscape.

Looking ahead, the success of initiatives like MaxSAF™ will be crucial in determining the pace of the aviation industry’s green transition. As production scales and technologies mature, the cost differential between SAF and conventional jet fuel is expected to narrow, further accelerating adoption. The collaborative model demonstrated by Montana Renewables, Calumet Montana Refining, and AEG Fuels highlights the importance of strategic Partnerships across the value chain. Ultimately, these developments are not just about producing a cleaner fuel; they are about building a resilient and sustainable infrastructure for the future of flight, one that balances economic viability with environmental stewardship.

FAQ

Question: What is MaxSAF™?
Answer: MaxSAF™ is a blended sustainable aviation fuel (SAF) launched by Montana Renewables. It consists of a nominal 50/50 mixture of renewable jet fuel and traditional fossil-based jet fuel.

Question: Is MaxSAF™ compatible with existing airplanes?
Answer: Yes, the fuel is certified under ASTM D7566 and D1655 specifications, making it a “drop-in” fuel that is fully compatible with existing aircraft and fueling infrastructure without any need for modifications.

Question: Who is producing and distributing this new fuel?
Answer: MaxSAF™ is produced by Montana Renewables, a subsidiary of Calumet, Inc., at their facility in Great Falls, Montana. The initial distribution to hubs in Montana, Washington, and Oregon is being handled by AEG Fuels.

Question: What are Montana Renewables’ future plans for SAF production?
Answer: The company has a major expansion initiative, supported by a conditional DOE loan guarantee, to increase its annual SAF production capacity to 300 million gallons. The first phase aims to bring 120-150 million gallons of capacity online by early 2026.

Sources: PRNewswire

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Sustainable Aviation

DHL Express Starts SAF Flights at Paris CDG With TotalEnergies Fuel

DHL Express signed a SAF deal with TotalEnergies covering 5 million liters in its first year for flights from Paris Charles de Gaulle.

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DHL Express Starts SAF Flights at Paris CDG With TotalEnergies Fuel
Photo: DHL

DHL Express has signed a sustainable aviation fuel (SAF) supply agreement with TotalEnergies whose initial phase covers 5 million liters over one year, for aircraft departing its hub at Paris Charles de Gaulle Airport (CDG). It is DHL Express’s first SAF use in France. The first SAF-powered DHL aircraft left CDG on November 9, 2026, the day the deal was announced.

In a press release dated November 9, 2026, issued from Bonn and Paris, DHL said it is the first express logistics provider to use SAF at CDG. The move coincides with the fifth anniversary of the Paris hub. DHL expects emission reductions of about 11,800 metric tons of CO2e a year in France, with the SAF flights running from CDG to its air hubs in Leipzig, Casablanca, Milan and London.

What the Paris agreement covers

DHL describes the deal as a first SAF supply agreement “over 5 million liters” for DHL Express air operations, and said its initial phase covers 5 million liters over the course of one year for aircraft departing the Paris CDG hub. DHL said the SAF is made from waste and residual materials such as used cooking oil, and works in existing aircraft and airport infrastructure without modifications. Compared with fossil jet fuel, it can cut lifecycle greenhouse gas emissions by about 80%, depending on feedstock and production method.

The volumes will also be included in GoGreen Plus, DHL’s book-and-claim offering, which assigns emission reductions to customers even when their shipments do not physically travel on SAF. DHL said customers can use it to reduce their Scope 3 emissions. SHEIN signed a GoGreen Plus agreement with DHL Express in March 2026 to use SAF supplied by DHL for its international express air freight.

Travis Cobb, executive vice president of global network operations and aviation at DHL Express, pointed to the share of SAF already used in DHL’s own fleet:

“In 2025, SAF already accounted for 10% of the aviation fuel used across DHL’s own aircraft fleet”

Philippe Prétat, CEO of DHL Express France, said the opening of the Paris hub in 2021 marked a major milestone, and that SAF use shows that strong logistics performance and a lower carbon footprint can go together. Mathieu Soulas, director of new mobilities at TotalEnergies, said “Sustainable Aviation Fuels are a key lever for reducing aviation emissions today.”

How the deal compares with DHL’s SAF targets

At 5 million liters, the Paris deal is small next to the supply agreements DHL Express has signed elsewhere. In March 2022, DHL announced deals with bp and Neste for more than 800 million liters of SAF until 2026, which it described at the time as among the largest SAF deals in aviation. In May 2026, DHL Express signed an offtake agreement with SAF One for 25,000 metric tons of unblended SAF a year from a plant in Bahrain, with production planned for 2028.

DHL’s stated aim is to raise SAF use to 30 percent by 2030, a goal it restated in May 2026 and that also appears in the Sustainability Roadmap it cited in March 2022. DHL said in March 2026 that SAF accounted for about 10% of fuel consumption in its dedicated air fleet in 2025, up from 3.5% in 2024.

TotalEnergies has been expanding its SAF output in France. In a June 16, 2025 release, the company said it expects to produce more than half a million tons of SAF a year from 2028, to cover the increase in the European SAF blending mandate, set at 6% for 2030. It said its Grandpuits biorefinery would have capacity for 230,000 tons a year of SAF in 2026, and that SAF coprocessing had begun at its Normandy platform. The company said it supplies SAF-blended jet fuel to airports including Paris-Le Bourget, Bordeaux and Toulouse, and that Air France-KLM had signed a deal for up to 1.5 million tons of SAF over ten years.

The Paris CDG hub at five years

DHL opened the CDG hub in 2021 with a EUR170 million investment, which it describes as its largest in France since entering the country in 1976. The site occupies a 91,000-square-meter plot with 34,000 square meters of operational space, and its sorting system handles up to 38,000 parcels and documents per hour. The hub runs 24/7 and employs 760 people.

The AirPro Atlas lists 72,029,407 passengers at CDG in 2025.

DHL also cited ground-side measures in France. It said all of DHL Express France’s owned light commercial vehicles are electric, that it serves 55 French city centers with low-emission delivery modes, and that this supports DHL Group’s target of two-thirds last-mile electrification by 2030.

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Singapore Airlines Signs SAF Offtake Deal with Aether Fuels

Singapore Airlines commits to buying SAF from Aether Fuels’ Project Beacon facility in Singapore, due online in 2028.

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Singapore Airlines Signs SAF Offtake Deal with Aether Fuels
Photo: Aether Fuels

Singapore Airlines (SQ) has finalized a firm purchase agreement to offtake next-generation Sustainable Aviation Fuel (SAF) from Aether Fuels, becoming the first carrier to commit to the upcoming Project Beacon production facility in Singapore.

Announced in a joint press release on 28 October 2026, the agreement transitions a previous memorandum of understanding into a binding contract. The deal secures future fuel volumes to support the airline’s target of replacing 5 percent of its total fuel consumption with SAF by 2030.

Transitioning from framework to firm commitment

The 28 October 2026 announcement builds on a Memorandum of Understanding (MoU) signed by the two companies on 4 February 2025. That initial framework outlined the airline’s intention to procure neat SAF for a five-year period, with an option to extend for an additional five years, once Aether commenced commercial production.

While the companies confirmed the transition to a firm offtake agreement, the exact fuel volumes and financial terms were not disclosed in the release.

Project Beacon and the Aurora technology

Aether Fuels, a climate technology firm incubated and funded in 2022 by Temasek-backed deep tech venture firm Xora, officially launched Project Beacon on 11 November 2025. The project is a partnership with Aster, a joint venture between Indonesian chemical and infrastructure company Chandra Asri and commodities trader Glencore.

The commercial-scale SAF facility will be located at Aster’s refining hub on Pulau Bukom in Asia-Pacific in Singapore. Aster acquired this site from Shell to develop a dedicated sustainable fuels footprint. Construction of the facility is scheduled to commence in 2026.

Once operational in 2028, Project Beacon is projected to produce 50 barrels per day, equating to approximately 2,000 tons of SAF annually. The plant will utilize Aether’s proprietary Aurora technology to produce Fischer-Tropsch Synthesized Paraffinic Kerosene (FT-SPK). According to Aether Fuels, this pathway is expected to deliver a minimum 70 percent reduction in greenhouse gas emissions compared to conventional jet fuel.

De-risking commercial scale-up

The firm offtake agreement follows a critical technical milestone for Aether Fuels. On 29 September 2026, the company announced the successful operation of a fully integrated demonstration line at RTI International in North America.

The 2.5 barrel-per-day system combined Aether’s Aurora Tri-Converter and Upgrader units with an existing Fischer-Tropsch reactor. The demonstration successfully converted renewable natural gas derived from landfill gas and captured industrial carbon dioxide into synthetic aviation fuel meeting ASTM D7566 specifications. This successful run provided the engineering data required to de-risk the design and scale-up of the Project Beacon facility ahead of its construction phase.

Singapore’s SAF ecosystem and airline targets

The aviation industry is increasingly reliant on SAF to meet decarbonization targets, but feedstock availability remains a primary bottleneck. Aether’s FT-SPK pathway addresses this by utilizing industrial waste gases and biomethane, bypassing the constrained agricultural and lipid-based feedstocks, such as used cooking oil, that dominate current SAF production.

The agreement aligns with broader regional regulatory shifts. The Civil Aviation Authority of Singapore (CAAS) has mandated a SAF levy for flights departing Singapore starting in 2026 to fund centralized SAF procurement. Singapore Airlines, which operates a fleet with an average age of under eight years, has committed to achieving net-zero carbon emissions by 2050.

AirPro News analysis

We view this firm offtake agreement as a clear indicator of the tightening future market for non-lipid SAF. The aviation sector’s reliance on Hydroprocessed Esters and Fatty Acids (HEFA) SAF is running into hard limits regarding used cooking oil and tallow availability. By committing to Aether’s FT-SPK product before the Project Beacon facility has even broken ground, Singapore Airlines is moving aggressively to lock in alternative feedstock pathways.

This early commitment is necessary for airlines aiming to meet 2030 mandates. The lead times for financing, constructing, and scaling novel waste-to-fuel facilities span several years, meaning airlines cannot wait for commercial production to begin before securing their supply lines.

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SABA Members Back Infinium eSAF Facility With Long-Term Deals

Google, McKinsey, and others sign binding SAFc agreements to support Infinium Energy’s 100,000 MT/year Texas eSAF project.

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SABA Members Back Infinium eSAF Facility With Long-Term Deals
Photo: Sustainable Aviation Buyers Alliance

Corporate members of the Sustainable Aviation Buyers Alliance (SABA) have signed binding, multi-year agreements to purchase sustainable aviation fuel certificates (SAFc) from Infinium Energy’s planned electro-sustainable aviation fuel (eSAF) facility in Texas. The commitments, announced on September 22, 2026, are designed to provide the financial demand signals necessary for Infinium to reach a final investment decision on the project.

In a press release issued by SABA, the organization confirmed that American Airlines (AA) will serve as the physical offtaker for the fuel, managing logistics and delivery. The corporate buyers purchasing the associated certificates include AVEVA, Bain & Company, Google, and McKinsey & Company. The agreement marks the first time SABA’s procurement model has been utilized to directly drive new production capacity for scalable sustainable aviation fuel.

Project Atlas production and environmental targets

Infinium Energy was selected through a SABA procurement process earlier in 2026 to provide ultra-low carbon eSAF. The fuel is produced using waste carbon dioxide and renewable energy, distinguishing it from traditional biofuel pathways that rely on agricultural or waste feedstocks.

The planned Texas facility, designated Project Atlas, is expected to have an annual sustainable aviation fuel (SAF) production capacity of 100,000 metric tons. According to the alliance, the contracted volumes will support an expected greenhouse gas abatement of 212,000 metric tons of carbon dioxide equivalent (mtCO2e). SABA equates this emissions reduction to approximately 3,500 commercial flights between John F. Kennedy International Airport (JFK) and Los Angeles International Airport (LAX).

“We’re proud to partner with SABA members including AVEVA, Bain & Company, Google, McKinsey, and others, as well as American Airlines to bring Infinium Energy’s next world scale eSAF facility to life. Their commitment reflects a shared conviction that decarbonizing aviation requires real investment in next-generation supply,” said Robert Schuetzle, CEO of Infinium Energy.

Aggregating demand through book-and-claim

The transaction utilizes a book-and-claim model. Corporate buyers purchase the SAFc to claim the environmental benefits against their business travel emissions, while the physical fuel is delivered to partner airlines. This mechanism allows corporations to fund SAF production even when the physical fuel cannot be delivered directly to the airports their employees use.

American Airlines will manage the physical integration of the eSAF into the commercial aviation fuel supply chain. Jill Blickstein, Chief Sustainability Officer at American Airlines, stated that the corporate commitments broaden participation in the SAF market and demonstrate how customers can collaborate with airlines and fuel producers to advance decarbonization.

SABA, a joint initiative of the Environmental Defense Fund (EDF), the Center for Green Market Activation (GMA), and RMI, has aggregated $500 million in SAFc demand from 35 companies to date. Aviation currently accounts for approximately 2 to 3 percent of global greenhouse gas emissions.

“Novel technologies are critical to meeting future demand for sustainable aviation fuel, but they will not be operational in time without investments made today. This procurement demonstrates how aggregated, long-term demand can help take promising eSAF projects from idea to reality,” said Jon Creyts, CEO of RMI.

AirPro News analysis

We view this agreement as a critical structural step for the eSAF market. Power-to-Liquid (PtL) fuels like those planned for Project Atlas face a steep commercialization barrier. They are highly capital-intensive to build and currently produce fuel at a significant cost premium compared to both conventional Jet A and HEFA-based SAF derived from waste fats and oils.

Airlines operate on thin margins and generally cannot absorb the full green premium of eSAF alone. By unbundling the environmental attributes from the physical fuel, the SABA model allows highly capitalized corporate entities like Google and McKinsey & Company to absorb that premium. More importantly, signing binding, multi-year offtake agreements provides the revenue certainty that infrastructure lenders require before financing first-of-a-kind industrial facilities. If Project Atlas reaches a positive final investment decision based on these contracts, it will validate the book-and-claim model as a viable financing mechanism for next-generation aerospace infrastructure.

Sources: Sustainable Aviation Buyers Alliance via PR Newswire

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