AerCap Delivers First 2 'Big Twin' Boeing 777-300ERSF Converted Freighters To Kalitta Air

The world’s largest aircraft lessor, AerCap, has delivered the first two Boeing 777-300ERSF Passenger-to-Freighter (P2F) converted aircraft, marking a major milestone for the lessor and the start of a new life for the Boeing 777 program. The two “Big Twin” aircraft were delivered to Michigan-based cargo operator Kalitta Air.

The aircraft were converted by Israel Aerospace Industries (IAI), a global leader in aircraft P2F conversions. The deliveries follow the receipt of the industry’s first Supplemental Type Certificate (STC) from both the Federal Aviation Administration (FAA) and the Civil Aviation Authority of Israel (CAAI).

The World’s First Triple Seven Conversion

Israel Aerospace Industries completed the conversion of the Boeing 777-300 from a passenger to a cargo aircraft earlier this month. The first two aircraft, including the prototype certification aircraft, were flown from Tel Aviv Ben Gurion Airport (TLV) to Detroit Metropolitan Wayne County Airport (DTW) and were immediately transferred to Oscoda-Wurtsmith Airport (KOSC).

The first aircraft (N77BCK) arrived on September 12, while the second aircraft (N770CK) arrived on September 13. Kalitta Air plans to put both aircraft into revenue service in early October, with further deliveries set to come over the next few weeks. The Boeing 777-300ERSF will replace Kalitta’s aging 747Fs, giving the airline more versatility and reducing its carbon footprint. AerCap CEO Aengus Kelly said,

“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.”

The 777-300ERSF Launch Operator

AerCap was the launch customer for the Boeing 777-300ERSF program, while Kalitta Air became the launch operator. Since its launch, the program has undergone extensive certification and testing with the FAA and CAAI to approve the aircraft to operate at a 100-tonne payload capacity. As one of the largest freighters, the 777-300ERSF will increase global shipping capacity, speed and efficiency.

Kalitta Air CEO Connie Kalitta said that the aircraft will give the airline greater range and payload capabilities to meet growing demand in the global air cargo market. The 777 converted freighter is set to offer lower operating costs than in-service aircraft, positioning it as a game changer in the evolving freighter market. IAI markets the “Big Twin” as having the following advantages compared to its counterparts:

The Boeing 777 is already a versatile aircraft platform. Boeing manufactured the 777-200, 777-300, and 777F variants and is now developing the next-generation 777X. The family includes the 777-8 and -9 for passenger operations and the 777-8 Freighter for cargo operations. The Triple Seven family is the best-selling widebody of all time, with the 777-300ER being the most successful widebody passenger variant, with over 800 deliveries.

Starting A New Life As A Freighter

The two newly converted Triple Sevens will start a new life as freighters after a purposeful life flying passengers around the world. Both aircraft were previously operated by Emirates. According to ch-aviation, N770CK took its first flight in May 2006 and accumulated 73,397 flight hours as of February 2023. N778CK was built in March 2005 and had accumulated 66,957 flight hours by May 2020.

Kalitta will take delivery of five more 777-300ERSFs, with some already converted and ready for delivery within the next few months. IAI has secured orders for about 60 converted freighters. The company offers conversions and upgrades for various commercial and military aircraft programs.

IAI was the world’s first company to convert a Boeing 777 into a freighter, following rigorous efforts to certify the aircraft over the past year. However, the program, like many other aircraft programs, faced delays, pushing back deliveries. As the ball is now rolling, IAI will expand its global footprint of conversion facilities for the Triple Seven. The company is also working on the 767FF (Fire-Fighter), a new aerial firefighting platform.