IAI completes the world’s 1st certified Boeing 777-300ERSF passenger-to-freight conversion
September 2, 2025
Israel Aerospace Industries (IAI) has become the first company in the world to complete a passenger-to-freighter (P2F) conversion of the largest Boeing 777, the -300ER, classified as the Boeing 777-300ERSF.
The milestone was confirmed with certification from both the US Federal Aviation Administration (FAA) and the Civil Aviation Authority of Israel (CAAI). The converted aircraft can carry up to 100 tonnes of freight, making it one of the largest commercial freighters available today.
Kalitta Air will be first to fly the Boeing 777-300ERSF
Dublin-based AerCap is the launch customer for the programme, with US cargo carrier Kalitta confirmed as the first operator.
IAI is the first company to complete a passenger-to-freighter (P2F) conversion of the Boeing 777, the world’s largest twin-engine jet. Until now, 777 freighters in service have all been factory-built by Boeing (the 777F variant, based on the 777-200LR).
“The company takes great pride in being the first in the world to convert a Boeing 777 into a freighter,” Levy said. “Receiving certification from aviation authorities highlights IAI’s technological, engineering and operational expertise and positions the company as a pioneer in this field.”
“We are excited to receive the STC certificate for the P2F conversion of Boeing 777 aircraft from both the FAA and CAAI,” says Yaacov Berkovitz, executive VP and general manager of IAI’s Aviation Group. “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.”
IAI achieves a world first with its certified Boeing 777-300ERSF
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 is the first to achieve a full, certified conversion.
The company is expanding its conversion facilities worldwide to meet growing demand, particularly for widebody freighters such as the 777, as e-commerce and global trade continue to fuel the need for additional cargo capacity.
Rising popularity of passenger-to-freight conversiions
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.
The airframe was delivered to TACA International Airlines in June 2010 and underwent conversion at Embraer’s facility in São José dos Campos, Brazil, starting last November.
The inaugural E190F is the first of two aircraft to be operated by Bridges Air Cargo, a Malta-based logistics carrier.
The company partners with leading shipment companies, including FedEx, DHL and UPS.
The Boeing 737 family dominates the P2F market. Airbus has also benefited from a new market in second-hand freighters with the deliveries of its first P2F aircraft.
In 2012, the Airbus conversion programme was launched in collaboration with ST Engineering and Airbus’ joint venture, Elbe Flugzeugwerke (EFW). In June 2015, the programme was extended to the A320/A321P2F family.
Qantas received the world’s first Airbus A321 passenger-to-freighter converted aircraft in 2020.
Analysts at Cirium told AGN last year that such conversions of old technology aircraft was a clear signal of shifting priorities as airlines invest in younger fleets, yet cargo demand continues to be high.
