The global air cargo industry is increasingly turning retired passenger aircraft into freighters as operators face a growing shortage of large cargo planes. With aging Boeing 747 freighters gradually leaving service, airlines are searching for cost-effective alternatives to support booming e-commerce demand.
To address the issue, companies are converting retired Boeing 777-300ER passenger jets into heavy cargo aircraft known as the 777-300ERSF. The conversion program is being developed by Israel Aerospace Industries and AerCap.
The modification process takes nearly five months and involves removing the passenger cabin, reinforcing the aircraft floor, and installing a large cargo door into the fuselage. The converted aircraft offers higher cargo volume, making it suitable for long-haul freight and fast-growing online shopping routes.
Kalitta Air became the launch operator of the new freighter type after receiving its first converted aircraft in September 2025. Industry experts say converting older passenger aircraft is far cheaper and faster than waiting years for newly built cargo jets, with total costs estimated at around 75 million US dollars per aircraft.
