Sustainable Aviation
SWISS Partners with Metafuels to Advance Synthetic Aviation Fuel Production
SWISS and Lufthansa Group partner with Metafuels to accelerate synthetic Sustainable Aviation Fuel production and meet EU 2030 mandates.
This article is based on an official press release from Swiss International Air Lines (SWISS).
On May 13, 2026, Swiss International Air Lines (SWISS), in coordination with its parent company the Lufthansa Group, announced a strategic partnerships with Zurich-based climate tech company Metafuels. According to the official press release, the collaboration is designed to accelerate the industrial-scale production of synthetic Sustainable Aviation Fuel (e-SAF). By securing early access to Metafuels’ proprietary technology, SWISS aims to proactively position itself ahead of strict European synthetic fuel mandates set to take effect in 2030.
The agreement outlines that SWISS and the Lufthansa Group intend to commit to long-term procurement contracts with Metafuels. This move highlights a growing industry trend where Airlines are partnering directly with deep-tech Startups to ensure future supply chains. The partnership also underscores Switzerland’s emerging role as a climate innovation hub, leveraging local research institutions to solve global decarbonization challenges.
Current global production volumes of synthetic aviation fuels are vastly insufficient to meet upcoming political and environmental targets. By collaborating with Metafuels, SWISS is taking a direct role in bringing viable synthetic SAF solutions to the commercial market.
The Shift to Synthetic Aviation Fuels
Overcoming the Limitations of First-Generation SAF
To understand the significance of this partnership, we must look at the limitations of current sustainable aviation fuels. Today, the vast majority of commercially available SAF is produced via the HEFA process (Hydroprocessed Esters and Fatty Acids), which relies heavily on waste oils and animal fats. Because these biological feedstocks are strictly limited in global supply, the aviation industry is being forced to transition to synthetic fuels, or e-SAF, to achieve true scalability.
According to the provided research data, Metafuels has developed a proprietary catalytic technology known as aerobrew. This process efficiently converts green methanol into aviation-grade jet fuel. The green methanol itself is produced by using renewable electricity to split water into green Hydrogen, which is then combined with carbon dioxide captured directly from the atmosphere or from biogenic waste sources.
Crucially, the resulting synthetic SAF is a “drop-in” fuel. This means it can be blended with conventional jet fuel, currently up to a 50 percent regulatory limit, and utilized in existing airport infrastructure and Commercial-Aircraft engines without requiring any technical modifications.
Scaling Up Production and Infrastructure
From Demonstration to Commercial Scale
Metafuels, founded in 2021 by Saurabh Kapoor, Leigh Hackett, and Ulrich Koss, has been rapidly expanding its operational footprint. Industry reports indicate that in early 2026, the company raised between $22 million and $24 million to pioneer its technology at a commercial scale, followed by a €1.92 million grant from the Dutch government in April 2026.
Currently, Metafuels operates a demonstration plant at the Paul Scherrer Institute in Villigen, Switzerland. This facility is capable of producing up to 50 liters of SAF per day to validate the aerobrew process. Simultaneously, the company is developing its first commercial-scale facility, dubbed “Project Turbe,” located in the Port of Rotterdam. According to project outlines, this facility aims to produce 10 tons of e-SAF per day by 2028, scaling up to 100 tons per day by 2031.
For the Lufthansa Group, which has committed to a carbon-neutral footprint by 2050, securing output from these future facilities is critical. The group has already seen success with its “Green Fares,” which allow passengers to offset flight emissions. In 2025, nearly 7 million Lufthansa Group passengers opted for these sustainable travel options, demonstrating strong consumer demand for decarbonized air travel.
“Future availability of sustainable fuels at sufficient scale will only be possible if investments in technologies and partnerships are made today. That is exactly what we are doing with Metafuels. We do not want to wait on the sidelines, but actively contribute to making synthetic fuels market-ready and scalable…”
Regulatory Pressures Driving the Market
Meeting the ReFuelEU Mandates
The driving force behind this procurement strategy is the impending regulatory landscape in Europe. Under the European Union’s “Fit for 55” package, the ReFuelEU Aviation Mandate legally requires aviation fuel suppliers to blend a minimum percentage of SAF into the fuel provided at EU airports.
The mandate began at a 2 percent overall SAF requirement in 2025 and will rise to 6 percent in 2030, eventually reaching 70 percent by 2050. More importantly for this partnership, the legislation includes a specific sub-mandate for synthetic aviation fuels (e-kerosene). Starting in 2030, 1.2 percent of all aviation fuel must be synthetic, rising to 35 percent by 2050.
“This agreement with SWISS and the Lufthansa Group is both a milestone for us and a clear affirmation of the role that synthetic SAF will play in the future of aviation… With both rising demand projected and tighter regulatory provisions ahead, synthetic fuels will only gain in importance.”
AirPro News analysis
As we analyze the broader aviation market, it is clear that the race for 2030 compliance has officially begun. SWISS’s partnership with Metafuels is a direct strategic maneuver to secure the supply needed to meet the 1.2 percent synthetic quota. Because the current global supply of e-SAF is virtually non-existent compared to projected future demand, airlines that fail to lock in early procurement contracts risk severe compliance penalties or exorbitant spot-market fuel prices by the end of the decade. By partnering with a local deep-tech startup, SWISS is not only hedging its regulatory risks but also investing in the localized energy security of the European aviation sector.
Frequently Asked Questions
What is e-SAF?
e-SAF, or synthetic Sustainable Aviation Fuel, is a type of aviation fuel made from renewable electricity, water, and carbon dioxide, rather than biological waste products like used cooking oil. It is considered infinitely scalable compared to first-generation SAF.
Why is SWISS partnering with Metafuels now?
SWISS is securing early access to Metafuels’ future production capacity to ensure it can meet the European Union’s strict mandate requiring 1.2 percent of all aviation fuel to be synthetic by the year 2030.
Can e-SAF be used in current airplanes?
Yes. The synthetic fuel produced by Metafuels’ aerobrew process is a “drop-in” fuel, meaning it can be blended with traditional jet fuel (up to a 50 percent limit) and used in existing aircraft engines without any modifications.
Sources: Swiss International Air Lines (SWISS) Press Release
Photo Credit: SWISS
Sustainable Aviation
Pilatus Aircraft Launches Carbon Reborn Sustainability Initiative
Pilatus Aircraft unveils Carbon Reborn to reduce carbon fiber waste and invest in solar aviation fuels for carbon-neutral operations.
This article is based on an official press release from Pilatus Aircraft.
Swiss aerospace manufacturers Pilatus Aircraft has unveiled its latest sustainability and manufacturing initiative, dubbed “Carbon Reborn.” The program highlights the company’s dual approach to carbon: maximizing the efficiency of carbon fiber composites in its aircraft while aggressively pursuing carbon-neutral operations through innovative fuel investments.
According to the official press release, Pilatus is focusing on reducing the environmental footprint of its manufacturing processes and fleet operations. The initiative underscores the critical role of lightweight materials in modern aviation and the industry’s broader push toward de-fossilization.
Advanced Composites and Waste Reduction
Enhancing the PC-24 and PC-12
Carbon fiber reinforced polymers (CFRP) have become a cornerstone of Pilatus’s aircraft design. The company’s flagship PC-24 Super Versatile Jet relies heavily on carbon and glass-fiber components to maintain a low base weight of approximately 5.3 tons. Industry data from Pilatus’s manufacturing partners indicates that this lightweight construction is essential for the jet’s unique ability to take off from short, unpaved runways of just 890 meters.
In a company press release, Pilatus emphasized its commitment to optimizing these materials. To address the environmental impact of composite manufacturing, the company has implemented advanced digital cutting technologies. According to manufacturing partner Zünd, these highly automated systems have successfully reduced carbon fiber waste rates from 30 percent to 20 percent at Pilatus facilities.
Global Supply Chain Integration
The “Carbon Reborn” strategy also extends to Pilatus’s global supply-chain. The company recently expanded its partnership with UAE-based Strata Manufacturing to produce composite trailing edge components for the PC-12 turboprop. By the first quarter of 2025, Strata had delivered 590 of these critical carbon-fiber components, demonstrating the scale of Pilatus’s composite integration.
Pioneering Solar Aviation Fuels
The Synhelion Partnership
Beyond physical materials, the “Carbon Reborn” initiative addresses atmospheric carbon through a strategic investment in Synhelion, a Swiss company developing solar fuels. Pilatus aims to transition its factory flight operations to be entirely free of fossil CO2 emissions.
“We see a future in which all Pilatus factory flight operations will be free of fossil CO2 emissions…”
– André Zimmermann, VP of Business Aviation at Pilatus
Synhelion’s “sun-to-liquid” technology uses solar heat to recombine water and atmospheric CO2 into hydrocarbon fuels. According to reporting by Skies Mag, Pilatus has stated its long-term goal is to roll out this sustainable aviation fuel (SAF) alternative to its entire global customer fleet, numbering over 4,400 aircraft, within the next decade.
AirPro News analysis
The “Carbon Reborn” initiative reflects a growing trend among business aviation manufacturers to tackle sustainability from multiple angles. While traditional SAF relies on biomass, Pilatus’s investment in solar fuels acknowledges the looming supply constraints of conventional sustainable fuels. By simultaneously reducing composite manufacturing waste and investing in synthetic crude technologies, Pilatus is positioning itself ahead of stringent European environmental regulations. However, the industrial scale-up of solar fuels remains a significant financial and logistical hurdle that the broader aviation sector will need to overcome.
Frequently Asked Questions
What is the Pilatus “Carbon Reborn” initiative?
It is a comprehensive strategy by Pilatus Aircraft focusing on the efficient use and waste reduction of carbon fiber composites in manufacturing, alongside investments in carbon-neutral solar aviation fuels.
How does carbon fiber benefit the PC-24?
The use of carbon and glass-fiber components keeps the PC-24’s base weight low (around 5.3 tons), allowing it to operate on short, unpaved runways that are typically inaccessible to traditional business jets.
What are solar fuels?
Solar fuels, developed by Pilatus partner Synhelion, are created using solar heat to synthesize water and atmospheric CO2 into liquid hydrocarbon fuels, offering a carbon-neutral alternative to fossil fuels.
Sources: Pilatus Aircraft
Photo Credit: Pilatus Aircraft
Sustainable Aviation
Germany Awards €350M Grant for Largest Sustainable Aviation Fuel Plant
Germany funds Brandenburg eSAF project with €350M grant to build the largest sustainable aviation fuel facility at Schwedt, aiming for 2030 production.
This article is based on an official press release from ENERTRAG and ZAFFRA.
The German federal government and the state of Brandenburg have officially awarded a €350 million grant to the “Brandenburg eSAF” project, marking a significant milestone in the development of sustainable aviation fuels (eSAF). According to a joint press release from ENERTRAG and ZAFFRA, the funding will support the construction of Germany’s largest industrial-scale eSAF production facility at the PCK refinery in Schwedt.
The project, previously known as “Concrete Chemicals,” represents a total investment exceeding €500 million. The facility is being developed by renewable energy company ENERTRAG and eSAF specialist ZAFFRA, a joint venture between Danish clean energy technology firm Topsoe and South African chemicals and energy group Sasol.
Once operational, the plant is designed to cover approximately 25 percent of Germany’s national eSAF blending obligation under the European Union’s ReFuelEU Aviation Regulation. The grant, which includes €245 million from the federal government and €104 million from Brandenburg, is the largest public funding award for a Power-to-Liquid project in Europe to date, according to the official release.
Scaling Up Sustainable Aviation Fuel
The Brandenburg eSAF facility aims to produce more than 30,000 tonnes of sustainable aviation fuel annually starting in 2030. The production process relies on green hydrogen generated through electrolysis powered by renewable electricity, combined with biogenic carbon dioxide.
Innovative Power-to-Liquid Process
According to the project partners, the biogenic CO2 will be supplied by LEIPA Georg Leinfelder, a local paper manufacturer in Schwedt. The green hydrogen will primarily be sourced via the H2 core network, specifically Gascade’s FLOW pipeline, supplemented by an on-site electrolysis plant. These feedstocks are then converted into eSAF using a Fischer-Tropsch synthesis process provided by ZAFFRA’s G2L eFuels platform.
The resulting fuel is expected to deliver lifecycle greenhouse gas reductions of more than 90 percent compared to conventional kerosene. The press release notes that the fuel is ASTM-certified for immediate use in existing aircraft infrastructure.
Regional Investment and Job Creation
Beyond its environmental goals, the Brandenburg eSAF project is positioned as a key driver for regional economic development and European energy security. By producing liquid fuel domestically using local renewable electricity, the initiative aims to reduce the aviation sector’s reliance on imported fossil fuels.
Securing the Industrial Future of Schwedt
The facility is projected to create approximately 150 permanent skilled jobs at the Schwedt site, along with up to 1,500 jobs during the construction phase. This investment is intended to reinforce the PCK refinery’s role in the local economy as it transitions toward a low-carbon model.
“Brandenburg eSAF brings together what belongs together: renewable energy from the region, Schwedt’s industrial heritage, and clear political commitment from federal and state governments. The result is a fuel that makes aviation climate-neutral and secures skilled jobs in the Uckermark region,” stated Dr. Gunar Hering, CEO of ENERTRAG, in the press release.
Engineering studies for the project are currently underway, led by the Griesemann Group, which was appointed in April 2026. The partners are targeting a Final Investment Decision (FID) by the end of 2027, with production scheduled to commence in 2030.
AirPro News analysis
At AirPro News, we note that the €350 million public investment in the Brandenburg eSAF project underscores the growing political and financial momentum behind Power-to-Liquid technologies in Europe. As the aviation industry faces stringent decarbonization mandates under the ReFuelEU Aviation Regulation, securing domestic, industrial-scale production of eSAF is becoming a strategic priority for national governments. The collaboration between established renewable energy developers and specialized chemical engineering firms highlights the complex, cross-sector partnerships required to bring these capital-intensive facilities online. If the 2030 production targets are met, this facility will play a critical role in proving the commercial viability of synthetic aviation fuels.
Frequently Asked Questions
What is the Brandenburg eSAF project?
It is an industrial-scale production facility for sustainable aviation fuels (eSAF) being built at the PCK refinery in Schwedt, Germany, developed by ENERTRAG and ZAFFRA.
How much funding did the project receive?
The project received a €350 million grant, split between the German federal government (€245 million) and the state of Brandenburg (€104 million).
When will the facility start producing fuel?
Production is scheduled to begin in 2030, with a target of producing more than 30,000 tonnes of eSAF annually.
Sources
Photo Credit: Angela Regenbrecht
Sustainable Aviation
Clean Planet Launches Pilot Facility Converting Plastic Waste to Aviation Fuel
Clean Planet Technologies opens a UK pilot facility converting non-recyclable plastic waste into Sustainable Aviation Fuel, reducing emissions by over 70%.
This article is based on an official press release from Clean Planet Technologies.
A major breakthrough in tackling both waste plastic and aviation emissions has been marked with the opening of the world’s first waste plastics to SAF (SAF) pilot facility. Operated by Clean Planet Technologies, the new Sustainability Innovation Centre is located at Discovery Park in Sandwich, Kent. The facility is dedicated to researching and developing new technologies to process non-recyclable plastic waste, beginning with its conversion into jet fuel.
The pilot facility addresses the growing problem of hard-to-recycle waste plastics and the environmental impact of the aviation industry. According to the company’s press release, the UK alone creates 5 million tonnes of waste plastics each year, 80% of which cannot be recycled and is treated as waste. Meanwhile, the world’s commercial aircraft consume 7 to 8 million barrels of jet fuel a day, with less than 1% currently produced from sustainable sources.
Transforming Waste into Sustainable Aviation Fuel
The new pilot facility integrates several stages into a single, controlled system optimized to transform hard-to-recycle plastics into SAF. The process begins with shredding the waste plastics to a uniform size, followed by pyrolysis, where the material is thermocatalytically converted into a synthetic crude oil in an oxygen-free environment. This melts the plastic rather than burning it.
After purification to remove impurities and contaminants, the pyrolysis oil undergoes distillation to separate it into relevant fractions. These fractions are then processed through Clean Planet Technologies’ patented hydroprocessing system, which uses hydrogen to further remove impurities and transform the properties of the product to meet stringent SAF specifications. The resulting ultra-clean, ultra-low sulfur fuel is sent for testing, blending, and evaluation as part of the American Society for Testing and Materials (ASTM) qualification pathway.
Reducing the Aviation Industry’s Carbon Footprint
The environmental impact of this technology are significant. According to Clean Planet Technologies, the process cuts lifecycle greenhouse gas emissions by more than 70% compared to traditional fossil jet fuel.
“Our process first heats the waste plastic with a chemical reaction to turn it into a liquid, rather than burning it. This is then treated with our patented process to remove impurities and create SAF that meets stringent commercial aviation specifications,” said Dr. Andrew Odjo, Chief Executive Officer at Clean Planet Technologies.
Dr. Odjo also highlighted the scale of the opportunity, noting that 100,000 commercial flights operate globally every day, while 600,000 tonnes of non-recyclable waste plastics enter the environment. The pilot facility aims to demonstrate that this waste can be turned into a premium product with quantifiable commercial demand.
Supporting UK and Global Sustainability Goals
The Sustainability Innovation Centre plays a critical role in bridging the gap between innovation and commercial development. It has been designed to support fuel and feedstock testing, validation, and progression through the ASTM qualification process. The facility has already secured financial support from the Department for Transport-funded UK SAF Clearing House.
We note that the fundamentals of the process,pyrolysis, purification, distillation, and hydroprocessing,are all technologies currently used independently at a commercial scale, which suggests that scaling up the integrated process will not present a significant challenge for the company.
Meeting the UK’s SAF Mandate
The opening of the pilot facility is an important step toward the UK’s ambition to support sustainable aviation and meet its SAF mandate.
“The Sustainability Innovation Centre is set up to demonstrate our patented waste-plastics-to-SAF process at pilot scale, supporting fuel testing, validation and progression. The important thing is that our pilot facility will support the growth of others, helping the UK to meet its SAF mandate,” added Dr. Katerina Garyfalou, Chief Operating Officer at Clean Planet Technologies.
UK government policy to decarbonize aviation fuel states that 2% of UK jet fuel demand must be SAF, increasing to 10% in 2030 and 22% in 2040.
Addressing Dual Strategic Challenges
Clean Planet Group, founded in 2018, views the new facility as a solution to two pressing global issues. By converting non-recyclable plastics,materials that would otherwise go to landfill or be incinerated,into low-carbon aviation fuel, the facility supports circular economy objectives.
“Our pilot facility addresses two strategic challenges simultaneously: plastic waste management and aviation decarbonisation,” said Clean Planet Group CEO Bertie Stephens.
Stephens noted that the pilot opens up new ways to make sustainable aviation fuel at a time when existing feedstocks, such as energy crops, are becoming harder to secure. It also positions the UK as a leader in turning waste plastics into SAF, supporting UK and European targets, and helping clear the path to commercial-scale plants later this decade.
Frequently Asked Questions
What is Sustainable Aviation Fuel (SAF)?
SAF is defined as any renewable or waste-derived aviation fuel that meets specific sustainability criteria. It is considered to have the greatest potential to reduce carbon emissions from international air travel.
How much of the UK’s plastic waste is currently recycled?
According to Clean Planet Technologies, the UK creates 5 million tonnes of waste plastics each year, and 80% of this cannot be recycled and is treated as waste.
How much does the new process reduce greenhouse gas emissions?
Clean Planet Technologies states that their process cuts lifecycle greenhouse gas emissions by more than 70% compared to traditional fossil jet fuel.
Sources
Photo Credit: Clean Planet Technologies
-
Regulations & Safety5 days agoFrontier Flight Hits Pedestrian on Denver Runway Causing Emergency Evacuation
-
MRO & Manufacturing5 days agoBoeing Proposes Fix for Grounded MD-11 Fleet with FedEx Return Plan
-
Regulations & Safety4 days agoDelta Worker Dies in Aircraft Tug Accident at Orlando Airport
-
Training & Certification3 days agoCAE Explores Strategic Alternatives for Flightscape Aviation Software
-
MRO & Manufacturing5 days agoIAI Advances Airbus A330-300 Passenger-to-Freighter Conversion