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South Korea Begins Boeing 777 Passenger-to-Freighter Conversion Project

South Korea initiates its first Boeing 777 passenger-to-freighter conversion at Incheon Airport, aiming to boost its aviation MRO sector and exports.

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This article summarizes reporting by Maeil Business Newspaper. This article summarizes publicly available elements and public remarks.

We are tracking a major development in the Asia-Pacific aviation maintenance, repair, and overhaul (MRO) sector. South Korea has officially initiated its first passenger-to-freighter (P2F) aircraft conversion project. According to reporting by Maeil Business Newspaper, a Boeing 777 passenger jet arrived at Incheon International Airport’s Advanced Aviation Complex on May 13, 2026, to undergo extensive structural modifications.

This milestone project is a collaborative effort involving the Incheon International Airport Corporation (IIAC), Israel Aerospace Industries (IAI), and domestic maintenance firm Sharp Technics K (STK). The initiative marks a strategic pivot for South Korea, transitioning the nation from a traditional flight operations hub into a specialized manufacturing and maintenance center for global aviation.

The Inaugural Boeing 777 Conversion

Timeline and Training Focus

The first aircraft slated for conversion is a Boeing 777 owned by AerCap Holdings N.V., recognized as the world’s largest aircraft lessor. The jet departed Istanbul, Türkiye, on May 1, 2026, before arriving at the Incheon hangar. Following the conversion process, the freighter is scheduled for delivery in October 2026 to Fly Meta, a Hong Kong-based aviation leasing and solutions provider that has been actively expanding its wide-body freighter fleet.

As detailed in the source report, the initial conversion will take approximately 180 days. While standard wide-body conversions typically require about 120 days, this inaugural project incorporates an additional 60 days specifically dedicated to workforce training and the establishment of systematic operational procedures. This upfront investment in human capital is designed to streamline future conversions and make South Korea a highly competitive player in the MRO market.

Strategic Partnerships and Facility Capabilities

The IAI and STK Joint Venture

The foundation for this P2F initiative was established in May 2021, when IIAC signed a Memorandum of Agreement with Israel’s state-owned IAI and South Korea’s STK, followed by a formal implementation agreement in 2023. IAI brings critical technology transfer to the region, holding the necessary certifications to convert Boeing 777-300ERs into freighters.

By transferring this highly specialized remodeling technology to South Korea, domestic companies will be empowered to directly manage the specifications of the parts needed for conversion. According to the source report, this localization is expected to significantly boost the domestic aviation parts industry.

The physical conversion is taking place within a newly constructed 2.5-bay hangar spanning 69,427 square meters at the Incheon Airport Advanced Aviation Complex. According to project specifications, this facility can simultaneously accommodate two wide-body aircraft and one narrow-body aircraft.

Economic Impact and Long-Term Vision

Scaling Production by 2040

South Korea has outlined aggressive growth targets for its MRO sector. IIAC plans to scale its operations to convert up to six aircraft annually by 2029. Looking further ahead to 2040, Incheon Airport aims to attract 92 aging aircraft for conversion.

With conversion costs estimated at 11 billion won per aircraft, the corporation projects this long-term initiative will generate 1 trillion won in cumulative exports and create 2,100 high-skilled jobs.

In a statement highlighted by Maeil Business Newspaper, Sang-Yong Lee, Head of the New Business Division at IIAC, emphasized the strategic goals of the project:

“Based on our world-class network and infrastructure competitiveness, we will actively attract leading global companies in aircraft maintenance…”

Acting President of IIAC, Kim Beom-ho, also confirmed the successful arrival ceremony on May 13, officially launching the cargo conversion program.

AirPro News analysis

We view South Korea’s entry into the P2F market as a timely response to global supply chain demands. The booming international e-commerce industry has created a massive requirement for high-capacity cargo aircraft. As older wide-body freighters, such as the Boeing 747, reach the end of their operational lifespans, airlines are increasingly turning to converted passenger jets to fill the logistical gap.

The converted Boeing 777-300ERSF, often referred to in the industry as the “Big Twin,” is particularly attractive to logistics operators. Industry data indicates it offers 25 percent more cargo capacity than older twin-engine long-haul freighters and consumes 21 percent less fuel than the Boeing 747F.

Furthermore, this cargo conversion facility acts as an anchor for Incheon’s broader strategy to build a comprehensive, one-stop aviation maintenance cluster. With Korean Air investing in a 176 billion won hangar facility and Trinity Airways (formerly T’way Air) developing new large hangars, the Advanced Aviation Complex is rapidly positioning itself as a premier MRO destination in the Asia-Pacific region. IIAC’s ongoing efforts to attract an aircraft painting hangar will eventually cover the final stages of aircraft maintenance, completing the local supply chain.

Frequently Asked Questions

What is a P2F conversion?

Passenger-to-freighter (P2F) conversion is the complex engineering process of modifying a retired or aging passenger aircraft into a dedicated cargo plane, thereby extending its operational lifespan and utility.

Who is receiving the first converted aircraft from South Korea?

The first converted Boeing 777 will be delivered to Fly Meta, a Hong Kong-based aviation leasing and ACMI/CMI solutions provider, in October 2026.

Why does the first conversion take 180 days?

While the industry standard for a wide-body conversion is 120 days, the inaugural project includes an extra 60 days for specialized workforce training and establishing rigorous operational procedures.

Sources

Photo Credit: Incheon International Airport Corporation

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MRO & Manufacturing

McFarlane Aviation Acquires Airglas to Expand Alaska Portfolio

McFarlane Aviation acquired Anchorage-based Airglas, Inc. on Sept. 30, 2026, adding backcountry skis and military components.

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McFarlane Aviation Acquires Airglas to Expand Alaska Portfolio

McFarlane Aviation has acquired Anchorage-based Airglas, Inc., integrating the specialized manufacturer of backcountry aircraft skis and cargo pods into its global distribution network while keeping production in Alaska.

Announced on September 30, 2026, the acquisition brings Airglas composite skis, heavy-duty nose forks, and fuel pods into the newly formed McFarlane Alaska brand. The move consolidates McFarlane Aviation’s hold on the ruggedized aviation modification market and provides Airglas with expanded international reach, according to the company’s press release.

Expanding the Alaska footprint

Airglas, founded in 1955, holds AS9100 certification and supplies equipment for general aviation aircraft, including Cessna, Piper, Maule, GippsAero Airvan, and Husky models. The company also manufactures specialized components for military rotorcraft, including the Boeing AH-64 Apache and Boeing CH-47 Chinook. Airglas currently serves customers in more than 30 countries.

Under the terms of the agreement, Airglas will maintain its manufacturing facility and workforce in Anchorage. McFarlane Aviation Chief Executive Officer Scott Still stated that adding Airglas to the company portfolio strengthens its commitment to the Alaska market and expands its general aviation and military business.

Adding Airglas to our family of brands strengthens our commitment to the Alaska market, expands our general aviation and military business, and advances our mission to keep customers flying. Wherever our customers fly, we want the equipment they depend on within easy reach.

Airglas Owner and President Shane Langland emphasized the importance of local production for specialized backcountry equipment. According to reporting by Aviation International News, Langland noted the acquisition provides a balance between local manufacturing and global sales.

We have spent decades building equipment for pilots who land where there is no runway. Joining McFarlane lets our team keep doing that work here in Alaska, while McFarlane’s distribution network puts our products in reach of pilots and mechanics around the world.

Consolidation in the backcountry market

The Airglas acquisition is the latest step in a broader consolidation of the Short Takeoff and Landing (STOL) and backcountry aviation modification sector. McFarlane Aviation, based in Baldwin City, Kansas, has systematically expanded its catalog of Parts Manufacturer Approval (PMA) components through targeted acquisitions of niche aviation brands, including previous purchases of PMA Products and CJ Aviation.

In 2022, the company acquired Airforms, a manufacturer known for engine baffles and Cessna Caravan components. This strategy accelerated in early 2026. On April 21, 2026, McFarlane launched the “McFarlane Alaska” brand, establishing a retail and distribution hub in Palmer, Alaska. According to Alaska Business Magazine, this move consolidated the product lines of recently acquired Alaskan Bushwheels and Airframes Alaska.

Airglas products are now immediately available through the McFarlane Alaska distribution network. Aviation International News reported that the full Airglas catalog will be integrated into the main McFarlane Aviation global distribution system by late 2026.

Corporate restructuring under TransDigm

The rapid expansion of McFarlane’s backcountry portfolio follows a major corporate transition for its parent organization. McFarlane Aviation operates under Victor Sierra Aviation Holdings. On April 7, 2026, aerospace conglomerate TransDigm Group completed a $2.2 billion acquisition of Victor Sierra Aviation Holdings and Jet Parts Engineering.

Backed by TransDigm Group capital, McFarlane now offers more than 35,000 parts. The integration of Airglas adds specialized composite manufacturing capabilities to this portfolio, particularly in the niche market of aircraft skis and heavy-duty nose forks designed for off-airport operations. The acquisition allows McFarlane to scale Airglas production through its established global supply chain while maintaining the specialized engineering knowledge base in Anchorage.

AirPro News analysis

We view the Airglas acquisition as a clear indicator that TransDigm Group intends to aggressively scale McFarlane Aviation’s footprint in the specialized aftermarket parts sector. By rolling legacy, family-owned Alaskan manufacturers like Airglas, Airframes Alaska, and Alaskan Bushwheels into a single corporate structure, McFarlane is effectively cornering the market for ruggedized STOL modifications. Keeping production in Alaska preserves the brand authenticity and specialized workforce required for these components, while routing sales through a centralized, global distribution network maximizes margin and volume.

Photo Credit: McFarlane Aviation

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Ontic Opens 72000 Sq Ft MRO Facility in Tewkesbury UK

Ontic opened a 72,000-sq-ft MRO facility in Tewkesbury, UK, consolidating aftermarket operations as part of a $30M global investment.

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Ontic Opens 72000 Sq Ft MRO Facility in Tewkesbury UK

Global aerospace manufacturer and aftermarket provider Ontic officially opened a 72,000-square-foot Maintenance, Repair and Overhaul (MRO) facility in Tewkesbury, Gloucestershire, on October 2, 2026. The site consolidates the company’s United Kingdom aftermarket operations into a single hub designed to support established aircraft fleets.

The opening represents a major milestone in a $30 million global investment strategy aimed at expanding Ontic’s MRO capacity, according to a company press release. The Tewkesbury site brings together 200 specialists, including engineers, technicians, and supply chain personnel, to provide lifetime repair and maintenance support for thousands of licensed product lines.

Expanding global aftermarket infrastructure

The Tewkesbury facility is equipped with dedicated IT systems and specialized infrastructure to handle complex aerospace repairs. Capabilities at the site include pneumatic and hydraulic testing, an ISO7 clean room avionics workshop, non-destructive testing (NDT), a machine shop, and a dark room.

In December 2025, the facility passed critical audits to achieve BSI AS9100 certification. It also secured Part 145 approvals from the UK Civil Aviation Authority (CAA), the European Union Aviation Safety Agency (EASA), and the US Federal Aviation Administration (FAA). Ontic expects to receive additional approvals from the Civil Aviation Administration of China (CAAC) in early Q4 2026.

“The opening of our Tewkesbury MRO facility marks a step-change in how we support our customers. By consolidating all our UK aftermarket expertise in one dedicated site, we are investing in the people, capability and infrastructure to consistently deliver a faster, more responsive and more transparent service. Alongside our new Miramar facility in the US, this is a significant milestone in our commitment to keeping established fleets flying safely for decades to come.”

The statement was provided by Brian Sartain, Chief Operating Officer of Ontic. Dave Mayne, MRO Director for Europe, added that the rapid launch of the site was driven by a focus on delivering immediate benefits to customers across product, people, and process decisions.

A broader strategy of acquisitions and capacity growth

The Tewkesbury opening follows a series of strategic expansions by Ontic to capture a larger share of the aerospace aftermarket. As major Original Equipment Manufacturers (OEMs) focus resources on new technologies and platforms, Ontic acts as a licensing partner, taking on responsibility for legacy and non-core product lines. By holding proprietary data, tooling, and test equipment, the company performs repairs to original OEM standards, offering obsolescence management and reducing operators’ total cost of ownership.

The $30 million global investment strategy previously funded the opening of a 64,000-square-foot MRO Center of Excellence in Miramar, Florida, in November 2025. To complement its MRO operations, Ontic signed a long-term lease in June 2026 for a 100,000-square-foot original equipment manufacturing facility in nearby Weston, Florida, with operations expected to begin in 2027.

The company has also pursued growth through acquisitions. On October 1, 2026, Ontic acquired Wichita-based Aero-Mach Companies, adding three aviation brands to its portfolio and further expanding its US footprint. Backed by CVC Capital Partners, Ontic now employs more than 1,700 people across 10 global sites in the US, UK, and Singapore.

Photo Credit: Ontic

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Bharat Forge and Pratt Whitney Canada Sign Supply Deal

Bharat Forge and Pratt & Whitney Canada sign a long-term supply deal backed by a new ring mill in Baramati, India, due in 2026.

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Bharat Forge and Pratt Whitney Canada Sign Supply Deal

Bharat Forge Ltd. and Pratt & Whitney Canada have finalized a long-term agreement for the supply of critical aerospace engine components, anchored by the construction of a new advanced ring mill in Baramati, Maharashtra.

Announced in a joint press release on August 1, 2025, the facility is expected to become operational in 2026. The agreement represents a significant expansion of India‘s domestic aerospace manufacturing capabilities and supports Pratt & Whitney’s strategy to build a resilient global supply chain.

Expanding the aerospace supply chain in India

The new Baramati facility will focus on processing specialty alloys required for high-stress aerospace forging applications. The ring mill is designed to support both domestic and international aerospace programs, supplying components directly to Pratt & Whitney Canada, a business unit of RTX.

Amit Kalyani, Vice-Chairman and Joint Managing Director of Bharat Forge Ltd., stated that the new facility marks a significant step in advancing India’s manufacturing capabilities in high-value aerospace components.

“We are excited to deepen our strategic relationship with Pratt & Whitney Canada through the establishment of this new ring mill. It not only reinforces our commitment to the global aerospace ecosystem but also marks a significant step in advancing India’s manufacturing capabilities in high-value aerospace components.”

Pratt & Whitney has maintained a presence in India for more than seven decades and currently employs more than 800 people in the country. Frederic Lefebvre, Vice President of Supply Chain at Pratt & Whitney Canada, noted that the agreement underscores the manufacturer’s commitment to building a resilient global supply chain and advancing the local aerospace ecosystem.

Transitioning to advanced aerospace manufacturing

Headquartered in Pune, Maharashtra, Bharat Forge is the flagship company of the Kalyani Group, which was founded in 1961. Historically recognized as a global provider of steel forgings and machined components for the automotive, railway, and energy sectors, the company has actively transitioned toward advanced aerospace and defense systems manufacturing.

The establishment of the dedicated aerospace ring mill aligns with the Indian government’s “Aatmanirbhar Bharat” initiative, which translates to a self-reliant India. The policy aims to boost indigenous manufacturing and defense capabilities, reducing reliance on imported components and systems.

As global original equipment manufacturers (OEMs) seek to diversify their supply chains, India has positioned itself as a primary destination for aerospace and defense manufacturing investment. The Baramati facility will allow Bharat Forge to process complex materials required for modern turbine engines, moving the company up the value chain from traditional forging operations into specialized aerospace metallurgy.

Recent developments in unmanned aerial systems

Following the August 2025 ring mill announcement, the two companies expanded their relationship the following year. On September 15, 2026, Bharat Forge and Pratt & Whitney Canada announced a collaboration to evaluate the integration of advanced turboprop engines into India’s High-Altitude, Long-Endurance (HALE) unmanned aerial vehicle (UAV) program.

The HALE UAV is currently being designed and developed by India’s Defence Research and Development Organisation (DRDO). Under the terms of the September 2026 agreement, Bharat Forge will lead the engine-airframe integration process. Pratt & Whitney Canada will be responsible for evaluating engine compatibility and overall performance metrics for the platform.

AirPro News analysis

We view the rapid progression of the Bharat Forge and Pratt & Whitney Canada partnership as a clear indicator of shifting global aerospace supply chain dynamics. The initial August 2025 agreement for the Baramati ring mill established a foundation for high-value component manufacturing. The September 2026 expansion into engine-airframe integration for the DRDO HALE UAV program demonstrates a much faster maturation curve.

Global OEMs are actively working to eliminate single points of failure in their supply networks. By moving beyond basic component supply and into complex systems integration within a 13-month window, Bharat Forge is proving that India’s domestic defense sector can absorb and execute advanced aerospace engineering tasks. This transition supports the broader strategic goals of the Aatmanirbhar Bharat initiative while providing Western engine manufacturers with a capable, scalable industrial base outside of traditional North American and European hubs.

Photo Credit: Bharat Forge

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