2 new conversions achieve certification in 2025

Two new freighter conversion programs received their STCs in 2025. While each was an achievement worthy of recognition, that number fell well short of expectations, with the forty-three-day U.S. government shutdown in the fourth quarter exacerbating delays. Industry executives agree that the regulatory environment has changed and that companies should be prepared to expend more time and money to certify freighter conversion projects going forward. The two conversions that obtained certification in 2025 were at opposite ends of the freighter spectrum. IAI 777-300ERSF [caption id="attachment_57294031" align="alignright" width="380"] IAI has redelivered at least eight 777-300ERSFs. (Photo/Cargo Facts)[/caption] IAI in 2025 became the first company to certify a 777 conversion. The FAA and the Civil Aviation Authority of Israel granted an STC for the 777-300ERSF program on Aug. 31, almost two years after IAI started its flight test campaign for the program in October 2023. It has been a long journey for IAI and co-investor AerCap, with the timeline shifting multiple times. In 2024, IAI had sent the first two units to the United States for tests with the FAA. With certification in hand, IAI has been quick to release completed aircraft to AerCap, which has delivered seven units on lease so far. Six (32789, 32792, 32791, 32785, 32787 and 32793) are in service with launch operator Kalitta Air , while one (32788) entered service with Air Atlanta Europe in early December. Meanwhile, Emirates in November sent its first feedstock unit (34481) to IAI’s facility in Tel Aviv (TLV) to kick off its own batch of ten conversions. Taby Air Maintenance Saab 2000F [caption id="attachment_57294032" align="alignright" width="380"] Unit 37 belongs to Jetstream Aviation Capital. (Courtesy/TAM)[/caption] The other freighter conversion project to receive regulatory approval in 2025 was Taby Air Maintenance’s Saab 2000F, which attained its EASA STC in November. The Sweden-based company is still awaiting validation from the FAA. Taby has only completed one aircraft (037) for launch customer Jetstream Aviation Capital, but will likely begin converting several more in 2026, it told Cargo Facts . After jointly launching the Saab 2000F program with Jetstream in 2022, Taby had to redesign the aircraft’s bleed air system in 2024 and EASA conducted additional analysis of the smoke evacuation system. Taby also holds the STC for the Saab 340 freighter conversion, having certified it in 2007. Upcoming approvals Three other conversion programs have told Cargo Facts they are close to achieving certification, possibly as early as the first quarter of 2026. They are: IPR Conversions’ large-cargo-door ATR 72-600F, the prototype (1239) of which has been completed at the Empire Aerospace facility in Coeur d’Alene, Idaho (COE), and will join FedEx ; KF Aerospace’s 737-800 Combi, the prototype of which (40852) arrived at Air Inuit’s facility in Montreal (YUL) in October after completion at the KF Aerospace facility in Kelowna, British Columbia (YLW); and Mammoth Freighters’ 777-200LRMF, the prototype of which (29742) conducted a test flight on Dec. 12. The company had hoped to obtain the STC before the end of 2025 , paving the way for unit 29742 to join Qatar Airways . Cargo Facts will present four invaluable events for airfreight professionals in the first half of 2026, starting with Cargo Facts LATAM, on Feb. 10-12. To see the agendas and register for the events, visit CargoFactsEvents.com .

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