Montana Renewables Launches MaxSAF to Expand Sustainable Aviation Fuel Access

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