AIRCRAFT - IAI’s Converted Passenger-to-Freighter Boeing 777-300ERSF Fleet Surpasses 20,000 Flight Hours

In less than just a year, IAI’s converted B777-300ERSF aircraft have accumulated more than 20,000 flight hours, another significant milestone for the world’s first and only B777 passenger-to-freighter conversion program

Israel Aerospace Industries (IAI), a world leader in passenger-to-freighter conversions, announced today that its Boeing 777-300ERSF known as “The Big Twin” has surpassed 20,000 cumulative flight hours since the first converted aircraft entered commercial service in September 2025.

To date, 11 Boeing 777-300ERSF aircraft have been successfully converted by IAI and are in operational use by customers across Europe, North America and Asia. Surpassing 20,000 flight hours in less than nine months reflects the program’s rapid transition from certification to commercial service and demonstrates the operational maturity and reliability of the world’s first and only Boeing 777 passenger-to-freighter conversion program.

With an average of more than 350 flight hours per aircraft each month, the converted fleet has demonstrated high operational utilization since entering service, supporting demanding cargo operations on international routes.

Since receiving the world’s first Supplemental Type Certificate (STC) for the Boeing 777-300ERSF conversion, the program has continued to expand. Additional Boeing 777-300ERSF aircraft are currently undergoing conversion, with more aircraft scheduled to enter the conversion process in the near and long term. In parallel, IAI continues to expand its global conversion network through additional conversion sites, increasing production capacity to support customers worldwide.

Alongside the continued growth of the Boeing 777-300ERSF program, IAI is also advancing its Airbus A330-300 Passenger-to-Freighter conversion program, further expanding its widebody conversion portfolio to address the evolving needs of the global air cargo market.




Boaz Levy, Chairman of Israel Aerospace Industries: “This milestone reflects the confidence our customers place in IAI and in the Boeing 777-300ERSF program. It demonstrates not only our engineering excellence, but also the aircraft’s proven operational reliability in commercial service around the world. As demand for advanced cargo aircraft continues to grow, we remain committed to delivering innovative, high-performance solutions that shape the future of global air cargo.”




Yaacov Berkovitz, EVP and GM of IAI Aviation: “Surpassing 20,000 flight hours in less than a year marks another milestone in the successful transition of the Boeing 777-300ERSF program from certification to full commercial operation. With 11 converted aircraft already flying




for customers across multiple continents, the program continues to demonstrate its reliability and value to cargo operators worldwide. The five additional aircraft currently undergoing conversion, together with additional aircraft scheduled to enter the conversion line, and the continued expansion of our global conversion network, reflect the growing confidence customers place in IAI and in the future of the Boeing 777-300ERSF.”




IAI is the world’s leading passenger-to-freighter conversion house, with more than four decades of experience and hundreds of converted aircraft delivered to customers worldwide. The company continues to expand its global conversion capabilities to support the growing demand for next-generation freighter aircraft.

FLEET - A Cargo Makeover: Introducing Emirates SkyCargo’s Boeing 777-300 ER Special Freighter

Dubai, UAE, 06 July 2026: A6-EBK is one of the latest aircraft to join Emirates SkyCargo’s growing fleet of dedicated freighters facilitating global trade and supporting businesses across the world transport goods to international customers. With increasing demand for air cargo capacity underlined by the rise in cross-border flow of goods such as e-commerce, the aircraft has already entered commercial service moving goods across multiple geographies through and to Dubai.

However, unlike other dedicated freighters in Emirates SkyCargo’s fleet, A6-EBK, a Boeing 777-300ERSF, is not a factory produced freighter. Instead, it is a special freighter (SF) that has been converted from a Boeing 777-300ER passenger aircraft from Emirates’ fleet.

Transforming a passenger configured 777-300ER into a cargo only aircraft was not simply a matter of removing seats and adding cargo doors. It was a complex process spanning several months that redesigned the aircraft’s structure, systems and operating philosophy to meet the demands of cargo transport. While maintaining the aircraft’s original aerodynamic performance and structural integrity without compromising operational safety, the conversion introduced extensive modifications to the fuselage, floor structure, loading systems, avionics, environmental controls and other systems within the aircraft.

Fuselage Modifications

As a first step, the aircraft’s interiors including seats, overhead stowage, galleys and lavatories were completely removed.  This allowed the team to modify the interior of the aircraft to accommodate cargo pallets.

A key characteristic of a freighter aircraft is its ability to carry large cargo pallets and this required the installation of a large maindeck cargo door. One of the most visible changes in the entire conversion process, creating the opening for this door required significant structural reinforcement and replacement of large sections of the fuselage structure.

Next, a rigid barrier with the ability to absorb any impact up to nine times the force of gravity (9G) was fitted at the front of the main deck, consistent with regulatory and safety configurations in a production freighter.

Freighters often carry a limited number of support staff in addition to the crew on long haul missions, such as grooms accompanying thoroughbred racehorses. To support the crew and additional members, a crew rest area and supplementary seating were installed during the conversion.

The flight deck was also modified to accommodate additional controls for environmental and safety systems optimised for the transportation of cargo.

Flooring and Cargo Management

In order to support heavier cargo pallets in the maindeck of the aircraft as compared to passengers, the floor structure used for passenger transport was completely removed and replaced with reinforced floor beams and a higher-capacity floor structure capable of supporting concentrated loads from heavy pallets and cargo handling equipment.

The conversion process included installation of a complete cargo loading system consisting of powered rollers, locks and guides was installed permitting ground crews to move large cargo units efficiently through the aircraft and secure them for flight. Additionally, an advanced cargo monitoring system including smoke detection and fire suppression was installed.

Aircraft Systems

Emirates SkyCargo offers a specialised suite of products to transport time and temperature sensitive cargo including life-saving medications and bio-innovations. This needs temperatures inside the aircraft to be maintained a specified ranges, sometimes as low as 5 degrees Centigrade. During the conversion, the environmental control system of the passenger aircraft was adapted to monitor and control airflow, ventilation, and temperature to support sensitive shipments such as pharmaceuticals and perishables. Other electrical systems were also modified to support the transportation of cargo.

Safety Certification & Final Preparations

Last but not the least, the conversion needed to achieve regulatory approval to show that the process met strict requirements around compliance with safety standards covering structural strength, systems reliability, fire protection and flight performance. This was demonstrated through extensive documentation, ground tests and flight evaluations before the aircraft could start transporting cargo.

Finally, the aircraft also received a full repaint and application of the latest Emirates SkyCargo livery ahead of its first commercial flight for Emirates SkyCargo.

Emirates SkyCargo is a global facilitator of trade transporting cargo across more than 150 destinations across six continents. The air cargo carrier has been steadily expanding its fleet in 2026 with six Boeing 777-F production freighters already delivered since March 2026 in addition to the converted freighter. The carrier is slated to receive a further four Boeing 777-F production freighters and one additional converted freighter later this year. This expansion of capacity is allowing Emirates SkyCargo to provide further customer choice and flexibility as well as support critical global supply chains and trade lanes.

 

FLEET - IAI and Fly Meta begin the inaugural conversion of the 777-300ERSF in Seoul (South Korea)

Photo: Ton Jochems-BUD

AI today inaugurated its new 777-300ERSF conversion line in South Korea with the induction of an aircraft for Fly Meta at the Sharp Technics K facility.
The 2013-vintage unit 41818 (ex-Turkish Airlines) arrived in Seoul (ICN) from Istanbul (ISL) on May 1. IAI hopes to complete conversion in about 180 days, it told Cargo Facts
Cargo Facts

 

FLEET - Ethiopian Airlines to lease two B777-300(ERSF) freighters

Ethiopian Airlines (ET, Addis Ababa International) has signed a lease agreement with AerCap for a pair of B777-300(ERSF) converted widebody freighters, representing the first of its type to operate in Africa. Deliveries are scheduled for the second quarter of 2028, the parties announced in a statement.

"These aircraft will significantly enhance our cargo capacity and efficiency, boosting trade in the region. As demand for air freight continues to grow, Ethiopian Airlines remains committed to investing in modern, sustainable solutions that cement our position in the global cargo market," commented Group CEO Mesfin Tasew.

"With 25% more capacity than today's smaller twin-engine long-haul freighters, the B777-300ERSF delivers significant cost efficiencies and will position Ethiopian Airlines to further expand its growing cargo platform," added AerCap CEO Aengus Kelly.

According to ch-aviation fleets data, Ethiopian Airlines already leases a pair of B767-300ER(BDSF) widebody freighters from Titan Aviation Holdings, but these are currently in maintenance. The rest of the cargo fleet includes three B737-800(SF)s, one B737-800(BCF), two B767-300Fs, and twelve B777-200Fs.
CH Aviation 

AIRCRAFT - AerCap Cargo Delivers First Two Boeing 777-300ERSF Passenger-to-Freighter Converted Aircraft to Kalitta Air

DUBLIN, Sept. /PRNewswire/ -- AerCap Holdings N.V. ("AerCap" or the "Company") (NYSE: AER) today announced it has delivered the first two Boeing 777-300ERSF Passenger-to-Freighter ("P2F") converted aircraft to Kalitta Air, including the prototype certification aircraft. The aircraft, which are part of a larger seven-aircraft order, arrived at Kalitta's facility in Oscoda, Michigan on September 12 and 13, respectively.

Kalitta Air became the launch operator of the AerCap Cargo 777-300ERSF conversion program in 2020, as part of their strategy to replace their ageing Boeing 747 freighter fleet. Since then, the program has undergone extensive certification and testing with the Civil Aviation Authority of Israel (CAAI) and the Federal Aviation Administration (FAA) to approve the aircraft to operate at a 100-tonne payload capacity.

Kalitta Air plans to place both aircraft into revenue operations in early October, with further deliveries of the aircraft taking place over the coming weeks.

"We are delighted to deliver the very first 777-300ERSF to our unwavering partner Kalitta Air, who have been with us shoulder to shoulder throughout this journey. With certification now received from both the CAAI and FAA, we are pleased to begin delivering the aircraft to our customers – a significant milestone for the program," said Aengus Kelly, CEO of AerCap.

Connie Kalitta, CEO of Kalitta Air, said, "Kalitta Air has always embraced new technology to serve our customers, and we are proud to be the launch operator for the first 777-300ERSF. This aircraft will give us greater range and payload capability to meet growing demand in the global cargo market."

 

AIRCRAFT - IAI completes conversion of first Boeing 777-300ERSF freighter

Supplemental Type Certificate received from U.S. FAA & Israeli CAA to convert B777, an aircraft able to carry 100 tons - poised to redefine the future air freighter market

Israel Aerospace Industries (IAI), a global leader in aircraft passenger-to-freighter (P2F) conversions, announced today following rigorous efforts over the past year, a landmark achievement in aviation history with the successful completion of the Boeing B777-300ERSF conversion from a passenger aircraft into a freighter, and the receipt of the industry’s first Supplemental Type Certificate (STC) certificate from both the U.S. Federal Aviation Administration (FAA) and the Civil Aviation Authority of Israel (CAAI). As one of the world's largest cargo aircraft, the newly certified B777-300ERSF will significantly increase global shipping capacity, speed and efficiency. This is a significant breakthrough in aviation and IAI is the first company in the world to convert an aircraft of this magnitude.
The Boeing 777 is poised to redefine the future of air freight with an impressive capacity of 100 tons and the ability to significantly reduce operating costs. This innovation positions the aircraft as a game-changer in the evolving global freighter market.

AerCap is the launch customer of the B777-300ERSF conversion program, while Kalitta will serve as the launch operator.

Boaz Levy, President and CEO of Israel Aerospace Industries: "IAI is a global leader in passenger-to freighter aircraft conversions, standing at the forefront of aeronautical technology and building on its extensive capabilities as Israel's largest aerospace company. The company takes great pride in being the first in the world to convert a Boeing 777 into a freighter. Receiving certification from aviation authorities highlights IAI's technological, engineering and operational expertise and positions the company as a pioneer in this field. This remarkable capability is the result of the company's professionalism and determination, paving the way for a broad expansion of our business activities with leading customers worldwide, and strengthening global e-commerce through advanced freighter aircraft solutions."


Yaacov Berkovitz, Executive VP and General Manager of IAI’s Aviation Group: "After years of dedicated effort, especially during the past year, we are excited to receive the STC certificate for the P2F conversion of Boeing 777 aircraft from both the FAA and CAAI – a breakthrough that reflects our commitment to innovation, engineering excellence and global leadership in aircraft conversions. This milestone sets a new standard in air cargo, delivering a unique combination of high payload capacity, volume and operational efficiency. The Boeing 777 was developed to meet the evolving needs of the cargo industry, and we believe it will become the preferred choice for international operators. I want to thank the aviation authorities and our team at IAI for their unwavering tenacity in bringing this transformative product to market.”
IAI is a world leader in passenger-to-freighter aircraft conversions, trusted by industry leaders such as Amazon, Gulfstream, DHL and others. Following the increasingly growing demand for freighter aircraft globally, the Company is expanding its global footprint of conversion facilities for the Boeing 777 aircraft.


For over 45 years, IAI has been a pioneer in the field of passenger-to-freighter conversions, delivering comprehensive solutions across all segments of the global aviation market. The company is recognized as the world’s leading conversion house, with unmatched expertise spanning a wide range of aircraft models and operations. Its broad portfolio includes passenger-to-cargo aircraft conversions, Maintenance, Repair, and Overhaul (MRO) services, business jet customization, aerostructures, aircraft upgrades and more.

Israel Aerospace Industries (IAI)

FLEET - Fly Meta to assign 777-300ERSF to Air Atlanta Europe

Fly Meta plans to place its first 777-300ERSF with Air Atlanta Europe for CMI service by the end of 2025, making the Malta-based carrier one of the first operators of the IAI Big Twin conversion.

 

FLEET - Challenge Group embarks on new chapter with launch of Boeing 777-300ERSF conversion program.

Challenge Group is proud to announce the official launch of its Boeing 777-300ERSF conversion program, marking another major milestone in the Group’s strategic fleet expansion plan.

As announced at the start of 2025, Challenge Group will introduce this year the Boeing 777-300ERSF converted freighter into its fleet. This move is set to be a true gamechanger for the organization, strengthening the Group’s existing network and opening up new markets with more efficient and sustainable airfreight and logistics solutions for customers worldwide.

With a payload capacity nearing 100 tons, the Boeing 777-300ERSF offers an ideal, competitive solution for high-volume and complex verticals, enabling Challenge Group to further develop strategic trade lanes and better serve global manufacturing hubs.

In a historic move, the Group has decided to register the first-ever Boeing 777-300ERSF in the EASA Region under a Maltese AOC (9H), reinforcing Malta’s growing role as a key aviation hub. The Group's teams are already actively working alongside the Maltese Civil Aviation Directorate to integrate the aircraft into the operating certificate, while recruiting and training new pilots for the type rating. This milestone follows the success of Challenge Group’s Boeing 767- 300BDSF conversion program, completed in 2024, and is part of a broader fleet modernization and growth strategy.

"After the successful completion of the Boeing 767-300BDSF conversion program last year, it’s time for a new challenge!" said Yossi Shoukroun, CEO of Challenge Group. "With the purchase of our very first Boeing 777-300ERSF, which has already been successfully relocated from its previous owner to the IAI (Israel Aerospace Industries) conversion plant in Tel Aviv, we are ready to embark on an exciting new journey, giving this passenger aircraft a second life in the world of trade. Additionally, our program foresees the conversion of three further aircraft, with options for an additional four, potentially bringing a total of ten Boeing 777-300ERSFs into our fleet within the next five years...Challenge Accepted!"

With the introduction of the Boeing 777-300ERSF, Challenge Group reinforces its commitment to becoming a key enabler of global trade, delivering tailored, integrated, end-to-end logistics solutions for complex verticals.
Challenge Group

Fleet Modernization -Air Incheon eyes B777-300ERSF

CargoFacts is reporting that Air Incheon is in talks with lessors to secure the lease of B777-300ERSFs. According to the news-article, the exact number hasn't been finalized but that it would be more than one. A first delivery is planned to take place in the second half of next year.

Air Incheon launched operations in 2013 and is currently a narrowbody-freighter airline, operating a fleet of four B737-800SFs. Between April 2018 and August 2019, the company did operate a widebody-freighter in the form of a single B767-300ERBDSF.

The airline is based at Seoul-Incheon and flies from there to destinations in China, Japan, and Mongolia.

 

Fly Meta to lease four Boeing 777-300ERSF

 Fly Meta to lease four Boeing 777-300ERSF aircraft from AerCap

The aircraft are scheduled to deliver in 2024 through 2025.