IAI Completes First-Ever Boeing 777-300ERSF Freighter Conversion, Paving the Way for a New Era in Global Air Cargo
Israel Aerospace Industries (IAI), a global leader in aviation and aerospace innovation, has announced the successful completion of its first Boeing 777-300ERSF passenger-to-freighter (P2F) conversion, a development that is being hailed as a significant turning point for the air cargo industry. The aircraft, often referred to by its industry nickname “The Big Twin,” has now received formal certification from both the US Federal Aviation Administration (FAA) and the Civil Aviation Authority of Israel (CAAI), paving the way for its commercial entry into service.
The conversion marks the first time in aviation history that a Boeing 777-300ER, a long-range passenger aircraft widely operated by leading airlines, has been transformed into a dedicated freighter. With a maximum payload capacity of 100 tons and the promise of lower operating costs compared to existing widebody cargo aircraft, IAI believes that the 777-300ERSF will reshape global cargo operations.
A New Chapter for Widebody Freighters
IAI’s Aviation Group, which has been at the forefront of passenger-to-freighter conversions for decades, views the 777-300ERSF as a natural progression of its expertise in this field. For many years, airlines have depended heavily on converted Boeing 747s, 767s, and 737s to meet growing demand for cargo transport. However, as global trade expands and e-commerce continues to accelerate, airlines and logistics companies are seeking aircraft that offer both larger capacity and improved fuel efficiency.
The Boeing 777-300ER, which entered service in the mid-2000s as a flagship for many long-haul passenger carriers, has proven itself as a highly reliable and fuel-efficient platform. With many of these aircraft now approaching retirement from passenger fleets, the timing is ideal for conversion into freighters. IAI’s engineering expertise has enabled the company to adapt the aircraft for cargo while maintaining the structural integrity and performance standards that made the passenger version so successful.
According to IAI, the 777-300ERSF will be able to carry up to 100 tons of cargo, positioning it between the iconic Boeing 747 freighters and the smaller Boeing 767 freighters. Its combination of range, payload, and operating economics is expected to make it a preferred choice for operators looking to optimize long-haul cargo routes.
Certification Milestone and Industry Recognition
The receipt of Supplemental Type Certificates (STC) from both the FAA and the CAAI is a crucial step that validates the safety, design, and engineering modifications of the aircraft. These certifications mean that the 777-300ERSF is now officially cleared for commercial operations under US and Israeli regulatory frameworks, opening the door for global deployment.
Boaz Levy, President and CEO of IAI, emphasized the significance of the achievement:
“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.”
Levy also noted that the project required years of intensive development, involving structural modifications, new cargo door installations, advanced avionics updates, and rigorous testing to ensure compliance with international safety standards.
A Strategic Partnership with AerCap and Kalitta
IAI’s success with the 777-300ERSF has been bolstered by its strategic partnerships. AerCap, the world’s largest aircraft leasing company, is the launch customer for the program, having placed an order for multiple conversions. Kalitta Air, a major US-based cargo airline with a global network, will become the first operator of the new freighter.
This collaboration underscores the market demand for a new generation of widebody freighters. AerCap’s involvement ensures that the aircraft will be widely available to customers around the world, while Kalitta’s operational expertise will help demonstrate the aircraft’s capabilities in real-world service.
Meeting the Needs of a Changing Cargo Market
The air cargo industry has undergone rapid transformation over the past decade. Driven by the rise of e-commerce, increased demand for just-in-time delivery, and supply chain disruptions caused by the COVID-19 pandemic, cargo airlines and integrators have been under pressure to expand capacity while managing costs.
The Boeing 777-300ERSF directly addresses these challenges. Its payload of 100 tons allows operators to transport larger volumes of goods in a single trip, while its twin-engine efficiency reduces fuel consumption compared to four-engine freighters like the Boeing 747. In addition, the aircraft’s extended fuselage length provides greater cargo volume, making it well-suited for e-commerce shipments, perishables, pharmaceuticals, and oversized freight.
Yaacov Berkovitz, Executive Vice President and General Manager of IAI’s Aviation Group, explained:
“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.”
Berkovitz added that the conversion was designed not just with today’s market in mind, but also with an eye toward the future, ensuring that operators have an aircraft that can adapt to evolving logistics demands over the next two decades.
Engineering Challenges and Innovations
Converting a Boeing 777-300ER into a freighter required significant engineering modifications. The most visible change is the installation of a massive cargo door on the main deck, allowing the loading of large containers and oversized freight. Structural reinforcements were made to the fuselage and floor to support heavy payloads, while advanced systems were integrated to manage cargo safety, weight distribution, and pressurization.
IAI’s engineers also incorporated new avionics and systems upgrades to ensure compliance with modern operational standards. The conversion program benefited from IAI’s extensive experience with previous aircraft types, including the Boeing 737, 747, and 767, but the 777 represented a new level of complexity due to its size and advanced design.
Market Impact and Industry Outlook
The introduction of the 777-300ERSF comes at a time when global airlines are reassessing their freighter fleets. With older 747s being phased out and rising concerns about fuel efficiency and emissions, the 777-300ERSF offers an attractive alternative. Industry analysts predict that demand for converted widebody freighters will remain strong for at least the next decade, as cargo traffic continues to grow at an annual rate of 4–5 percent.
For IAI, the successful certification of the 777-300ERSF strengthens its position as a global leader in freighter conversions. The company has already announced plans to expand its conversion facilities to meet rising demand, with sites in Israel and abroad preparing for large-scale production.
Moreover, the program is expected to contribute significantly to Israel’s economy by creating high-skilled jobs in engineering, manufacturing, and aviation services. It also reinforces IAI’s reputation as an innovator capable of delivering complex aerospace projects that compete on the world stage.
A Gamechanger for Air Cargo
The completion and certification of the first Boeing 777-300ERSF freighter conversion marks a historic milestone for Israel Aerospace Industries and the broader aviation sector. By transforming one of the world’s most successful passenger aircraft into a state-of-the-art freighter, IAI has introduced a platform that combines capacity, efficiency, and long-range capability in ways that could redefine global cargo logistics.
With AerCap as its launch customer and Kalitta Air as its launch operator, the 777-300ERSF is set to make an immediate impact on international cargo routes. As airlines and logistics companies seek sustainable, cost-effective solutions for the future, the aircraft is positioned to become a central player in the next chapter of air cargo transportation.
IAI’s achievement is not only a technical triumph but also a strategic milestone, signaling the dawn of a new era where advanced passenger-to-freighter conversions will play a critical role in supporting the world’s growing demand for fast, efficient, and reliable air transport.