FedEx expands fleet with new Cessna 408 SkyCouriers, ATR 72-600Fs

Over the past twelve months, the regional freighter sector has continued to thrive even as other carriers streamline operations by removing freighters from service and delaying or canceling orders for new and converted freighters. A significant factor driving regional freighter growth has been the demand for next-day delivery to smaller and mid-size cities, led by companies like Amazon, FedEx, UPS, and DHL, according to Jetstream Chief Executive Stuart Klaskin in an interview with Cargo Facts in 2023.   

 In a strategic move to modernize and diversify its fleet, FedEx has significantly expanded its operations with the addition of new Cessna 408 SkyCouriers and ATR 72-600Fs. Textron Aviation, the company behind the Cessna brand, recently delivered its tenth Cessna 408 SkyCourier to FedEx, continuing a pattern of growth that reflects the express carrier’s commitment to enhancing its regional and global capabilities 

Textron Aviation’s Delivery of the Cessna 408 SkyCourier and Empire Airlines Expansion 

On June 2, Textron Aviation delivered the aircraft (408-0015) to FedEx, which arrived in Spokane, WA, from Wichita, KS. This unit, like its predecessors, was allocated to Hayden, Idaho-based Empire Airlines for CMI (Crew, Maintenance, and Insurance) operations. FedEx has strategically divided its SkyCouriers between Empire Airlines and Mountain Air Cargo, aiming to optimize regional delivery and overall logistics efficiency. 

Empire Airlines now operates five SkyCouriers, with recent additions reflecting a broader trend of fleet modernization. Mountain Air Cargo, the first operator to launch commercial service with the SkyCourier, continues to be a key player in this deployment. 

Empire Airlines has seen a rapid expansion of its new-generation feeder fleet. CEO Tim Komberec expressed strong enthusiasm for the SkyCourier, highlighting its significance to the feeder system. Since becoming the second operator of the SkyCourier, Empire has integrated multiple units into its operations, underscoring the aircraft’s importance in meeting regional cargo needs. 

Beyond Empire Airlines and Mountain Air Cargo, other operators of the SkyCourier include Kamaka Air, Bering Air, and soon Everts Air Cargo. Additionally, Textron delivered the first passenger version of the SkyCourier to Hawaiian carrier Lanai Air, marking a milestone in the aircraft’s versatility. This delivery highlights the SkyCouriers adaptability not only for cargo but also for passenger transport, expanding its potential applications across different sectors. With such diverse uses, the SkyCourier is set to become an integral part of regional air services for a variety of operators. 

FedEx’s Broader Fleet Expansion and ATR 72-600 Freighter Plans  

FedEx’s fleet expansion is not limited to the SkyCourier. The company continues to bolster its regional fleet with new ATR 72-600Fs. The recent delivery of its fifteenth ATR 72-600F to Mountain Air Cargo is part of this broader strategy. These aircraft play a crucial role in FedEx’s regional operations, enhancing capacity and efficiency. 

The newest ATR 72-600F (MSN 1753) joined the Mountain Air Cargo fleet in Kinston, N.C., and is the third of its kind operated by the carrier. Mountain Air Cargo took delivery of N706FE (MSN 1739), their first ATR 72-600F, in March 2023, and it entered service later that same month. Fastforward four years since FedEx’s first delivery in 2020, 19 aircraft are now in service. FedEx has placed these aircraft with various CMI partners, including ASL Airlines Ireland, IFL Group (Gulf & Caribbean Cargo), Empire Airlines, and the previously mentioned Mountain Air Cargo reflecting a diversified operational approach, with a new operator on the horizon. 

Swiftair’s Role and European Operations 

In a notable expansion of its European operations, FedEx has introduced Swiftair as the latest CMI operator for its ATR 72-600Fs. The latest delivery (unit 1762) made its way from Toulouse, France, to Madrid, Spain, on July 12th, marking Swiftair as the first Spanish carrier to operate this type. A training flight took place on July 18th, and we are close to service entry. This strategic move enhances FedEx’s European network, joining ASL Airlines Ireland in operating these freighters. 

Figure 1 – FedEx Feeder fleet by operator

Outlook for FedEx’s Fleet Expansion 

FedEx’s ambitious plans include adding 17 Cessna 408 SkyCouriers and seven ATR 72-600Fs by 2025, and 14 SkyCouriers and three ATR 72-600Fs by 2026. This expansion is part of a broader strategy to modernize its fleet while addressing operational challenges, including pilot overstaffing and cost reductions. 

Strategic Cost Reductions and Fleet Optimization 

FedEx is implementing significant cost-cutting measures, including reducing guaranteed flight hours for pilots and pushing for early retirements to address overstaffing. cargo jets.  

In its latest fiscal fourth-quarter report, FedEx Express (FX) announced the retirement of 22 Boeing 757 Freighters, resulting in a $157 million impairment charge. This downsizing reduces its total trunk aircraft fleet to 389, from 407 last year. Alongside, FedEx also retired nine MD-11Fs as part of its fleet restructuring, leaving it with 92 Boeing 757Fs and retiring seven associated engines. These measures are part of a multi-year initiative aimed at achieving $1.8 billion in permanent cost reductions for the fiscal year and $4 billion by 2026. 

Despite these reductions, FedEx continues to modernize its fleet, adding 10 Boeing 767 Freighters and four Boeing 777 Freighters, with further deliveries planned through 2025. These updates are part of an effort to replace older models like the Airbus A300-600RF and MD-11F. 

Autonomous Flying and Future Innovations 

In their 2023 annual report FedEx cited “difficulties experienced by the companies with which we contract to fly smaller regional ‘feeder’ aircraft in attracting and retaining pilots” as a potential risk & uncertainty. To neutralize this risk, FedEx is exploring innovations in autonomous flying. Reliable Robotics has conducted trial flights with a Cessna Caravan, highlighting the potential for unmanned operations. This technology could significantly impact regional cargo carriers and address long-standing difficulties stemming from pilot shortages. 

Mainline routes transferred to Feeder Operations 

Another cost-saving initiative from FedEx is deploying ATRs on routes previously operated by 757s. One of the most notables of these changes is the deployment of a Gulf and Caribbean Cargo ATR on FedEx’s puzzling San Deigo (SAN) to Tijuana (TIJ) route, previously FX69/70. Only 18 miles separates the two airports, however when you factor in the departure and arrival queuing the route becomes significantly longer. Originally, started in March 2020, many attributed this route to cross border pandemic complications and congestion at the Mexico/US land border, the latter was likely the cause. The transition to ATR ops occurred on August 30th, 2023, and continues today. Previous articles hinted that this 757 may have been a standby aircraft that could quickly be redeployed on other routes within the FedEx next work, however now that a smaller aircraft is being operated FedEx may have traded flexibility for cost savings. 

Figure 2 – Route map by operator

Conclusion 

The expansion and modernization of regional freighter fleets reflect a strategic approach to enhancing operational capabilities and efficiency across the industry. This segment is expected to grow by about 70% over the next 20 years, driven by the rise of e-commerce and express shipping. In the past year, there has been unprecedented activity in this sector, with multiple product launches and new operators entering the market. While FedEx’s addition of new Cessna 408 SkyCouriers and ATR 72-600Fs exemplifies these trends, the broader industry is also seeing a shift towards larger, cost-efficient turboprop aircraft, such as the ATR series. This shift is critical as operators worldwide focus on cost-cutting measures and innovative technologies to navigate future challenges. Regional freighters are thus becoming increasingly vital in maintaining and enhancing the efficiency and reach of global air cargo networks.