IBA, the aviation market intelligence and advisory firm, has reported a sharp rise in demand for Boeing 777-300ER passenger-to-freighter (P2F) conversions. This surge is being driven by a growing need for large wide-body freighter capacity and the looming end of Boeing 777F production in 2027, following ICAO emissions mandates. However, despite heightened interest from airlines and leasing companies, a critical shortage of feedstock is slowing the pace of conversion.
Operators are retaining their 777-300ER fleets longer due to high passenger demand and elevated residual values. Some carriers have even initiated unplanned cabin refurbishments, suggesting an extended lifespan for these aircraft in passenger service. As a result, the availability of suitable aircraft for conversion remains limited, placing upward pressure on acquisition and conversion costs.
IBA estimates that converting a 777-300ERSF in half-life condition costs between US$75–80 million, rising to nearly US$100 million if the GE90-115 engines require maintenance. This financial burden may restrict participation to those with substantial capital resources.
The 777-300ERSF programme, developed by Israel Aerospace Industries (IAI) in partnership with AerCap, is nearing FAA certification. Kalitta Air’s first converted aircraft has completed test flights in the US, with four more units from AerCap’s portfolio already converted at IAI’s Tel Aviv facility and due to enter Kalitta’s fleet. Additional conversion lines are located in Abu Dhabi, Seoul, and Marana, California, with expansion expected once certification is finalised.
Mammoth Freighters is also progressing, with test flights of its 777-200LRMF prototype under way and Qatar Airways named as launch customer. This variant will form the basis for Mammoth’s future 777-300ERMF conversions, with AviaAM Leasing confirmed as launch customer. Conversion work is ongoing at Aspire MRO’s Texas facility and STS Aviation’s Manchester hangar.
Meanwhile, Kansas Modification Centre’s 777-300ERCF programme is advancing at a slower pace but contributes to the limited set of options available for wide-body cargo operations.
As freighter choices narrow with the phase-out of the 747-400F and delays to the 777X, recent 777F orders from carriers like Emirates highlight a strategic shift in fleet planning. For many, new-build freighters remain prohibitively expensive, reinforcing the urgency and importance of P2F conversions to meet the growing global demand for efficient cargo aircraft.
