On September 1, 2025, Israel Aerospace Industries (IAI) announced the completion of the first-ever passenger-to-freighter conversion of a Boeing 777. This achievement marks a significant milestone in the history of air cargo and opens up new opportunities for extending the life of older, wide-body aircraft.
A Breakthrough in Air Cargo
The conversion resulted in the creation of the B777-300ERSF, based on the Boeing 777-300ER. This model is now one of the largest twin-engine cargo aircraft on the market, with a payload capacity of up to 100 tonnes. A key advantage of the new model is its 25% greater volume compared to the factory-built B777-200F and a 21% reduction in fuel consumption per tonne of cargo compared to the classic B747-400 freighter, contributing to lower operating costs.
IAI has received its first Supplemental Type Certificate (STC) from the US Federal Aviation Administration (FAA) and the Civil Aviation Authority of Israel (CAAI), authorising the commercial operation of the converted aircraft in compliance with international safety standards.
Converting a Boeing 777 into a freighter costs between $264 and $340 million, significantly less than the price of a new-build cargo aircraft. This cost difference allows airlines to keep the aircraft operational for up to 50 years post-conversion, making it a highly cost-effective solution.
Cost-Effectiveness and Extended Lifespan
With the growing demand for air cargo, coupled with the drive for greater efficiency and more environmentally friendly operations, the Boeing 777 P2F (Passenger-to-Freighter) is an attractive option for international cargo carriers. This model delivers significant improvements in volume and efficiency, aligning perfectly with current trends in logistics and e-commerce.
IAI, a key player in the aircraft conversion market, is collaborating with AerCap, the launch customer for this programme. AerCap, in turn, has delivered the first converted aircraft to Kalitta Air, a move that underscores the market’s confidence in IAI’s quality and innovative approach to aircraft conversions.
Strategic Partnerships and Customer Confidence
IAI is not the only company in this sector. Other firms, such as Mammoth Freighters and the Kansas Modification Center, are also developing their own Boeing 777 conversion programmes, competing for a share of the growing freighter market.
Boaz Levy, President and CEO of IAI, commented on the project’s success: “We are proud to be the first in the world to complete the conversion of the Boeing 777 into a freighter and to receive the necessary certifications. This achievement reflects our technological and engineering excellence and strengthens our leading position in the aircraft conversion market.”
The B777 P2F project represents a key step towards a more modern, efficient, and sustainable air cargo model, one that has the potential to fundamentally transform the entire industry.
Source: Aerotime
