World’s 1st Boeing 777-300ERSF passenger to freight conversion enters service with Kalitta Air
September 16, 2025
Kalitta Air has become the launch operator of the Boeing 777-300ERSF, taking delivery of the first two aircraft from AerCap in mid-September.
The freighters, which include the prototype certification airframe, were handed over at Kalitta’s Oscoda, Michigan base on 12 and 13 September.
They are the first of a seven-aircraft commitment and are scheduled to enter revenue service in early October.
Developed as part of a conversion programme launched in 2019, the 777-300ERSF is designed to replace older Boeing 747 freighters with an aircraft capable of carrying up to 100 tonnes of payload.
The Big Twin enters the freighter market
The 777-300ERSF, marketed as “The Big Twin”, is the first passenger-to-freighter conversion for the long-range 777-300ER, the best-selling widebody passenger jet with more than 800 deliveries.
Offering a payload of 100 tonnes and a volume capacity of 811 m³, it promises up to 20% lower CO₂ emissions per tonne compared with the 747F.
The programme is led by AerCap and Israel Aerospace Industries (IAI), which pioneered widebody conversions including the first 777-300ER passenger-to-freighter.
It was jointly overseen by the Civil Aviation Authority of Israel (CAAI) and the US Federal Aviation Administration (FAA), with certification secured at the beginning of September.
The aircraft are expected to play a pivotal role in reshaping the large widebody freighter market as operators transition away from older four-engine types.
IAI first to complete the 777 P2F
IAI is the first company in the world to complete a 777 P2F conversion, with Dublin-based AerCap as the launch customer for the programme, and US cargo carrier Kalitta the first operator.
Aengus Kelly, CEO of AerCap, 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 programme.”
Kalitta Air founder and CEO Connie Kalitta added: “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.”
Buoyant conversion market
IAI has been active in passenger-to-freighter conversions for more than four decades and counts Amazon, DHL and Gulfstream among its customers.
While competitors are also chasing the ‘big twin’ dream, including Mammoth Freighters, Kansas Modification Center and EFW in Europe, IAI was the first to achieve a full, certified conversion.
It has been a year of firsts for P2F conversions.
Earlier in the summer, the first Embraer passenger-to-freight conversion, an E190F, arrived in Europe ahead of its entry into service later this year.
The aircraft, leased from Regional One to Bridges Air Cargo, landed at Maastricht Airport on 1 August.
