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Flipping the Boeing 777-300ER to Cargo :GECAS has partnered with Israel Aerospace Industries on the program

The Boeing 777-300ER widebody passenger jet is the workhorse of long-haul aviation. Powered by a pair of giant GE90 engines — for a long time the world’s most powerful jet engine — the planes have allowed airlines to link continents and cities as distant as Los Angeles and Dubai with frequent nonstop flights.

But early this summer, one specimen arrived at an Israeli airfield set for a dramatic transformation into an air cargo freighter. The plane is a prototype for a program to convert 15 of the giant planes into a cargo configuration that will each be able to carry 100 tons of goods around the globe. As the 777-300ER replaced the iconic four-engine 747 jumbo jet for passenger airlines, the 777-300ERSF — with the “SF” indicating “special freighter” — is set to bring the same twin-engine efficiencies to cargo operators.

From the first blueprint to the first payload, the conversion program involves over 200 people and will take approximately 39 months to clear the myriad of steps including concept definition, design phases from preliminary to critical, physical conversion, and regulatory certification hurdles. For example, the team needs to cut major sections of the fuselage to fit the new cargo door, install a rigid barrier that can withstand forces up to 9 g’s and replace the entire composite floor structure with reinforced aluminum.

The team plans to transform the passenger deck into a full cargo compartment by modifying existing passenger doors and windows. The plane is expected to be able to carry many different kinds of cargo, including express shipments, online orders and perishables, as well as oversized freight — including even live horses or aircraft engines.

The plan also includes a supernumeraries compartment — basically, quarters for crew and company employees — right behind the pilots’ cabin where the galleys, lavatories, passenger seats and other areas were located. “Everyone thinks converting an aircraft from passenger to freighter is a simple process,” says Richard Greener, senior vice president and manager of GECAS Cargo, the freighter platform within GE Capital’s aviation finance business. “Instead it involves similar principles and regulatory requirements that you would face when producing a factory new build aircraft.”

GECAS has partnered with Israel Aerospace Industries on the program to convert the planes for planned delivery in late 2022 for operating lease to GECAS customers.

The first step is measuring every part of the fuselage to get an accurate rendition of the plane on the computer drawing board. Engineers use finite element modeling and extensive ground and flight tests to analyze how the conversion will affect the aircraft. With planned changes to include a new floor, adjustable storage configurations, a wider door and a cargo-loading system, engineers assess the shifts in stress on the plane’s fuselage to determine what additional modifications are needed. “What we’re doing is really re-engineering the aircraft,” Greener says.

The goal is to minimize the weight of the plane and maximize the payload to make it as cost-efficient as possible. When the conversion is complete, the 777-300ERSF, aka the “Big Twin,” will be able to carry something as large as a GE90 aircraft engine on the main deck as well as express and e-commerce cargo.

Greener said he expects a significant milestone will come around next June. That’s when engineers will cut into the plane’s fuselage and bring the freighter design to life. “New structures such as the main-deck cargo door and cargo-loading system will be added to the aircraft and the transformation from passenger to freighter will begin,” he says.

Meanwhile, as the engineers make their changes to the plane’s designs, Israel Aerospace Industries will be working closely with the Civil Aviation Authority of Israel, U.S. Federal Aviation Administration and the European Union Aviation Safety Agency to validate the work and obtain the necessary approvals and certifications.

These conversions are expected to be a growing business for GECAS as cargo traffic is expected to grow significantly in coming years. Last year, for example, GECAS started leasing converted Boeing 737-800BCF jets to Amazon. Boeing projects that such market segment will double over the next 20 years, and that the world’s freighter fleet will expand from about 1,870 to 3,260 freighters. More than 60% of the new volume will be passenger-to-freighter conversions.

More information about the 777-300ERSF can be found on the program’s website. And in case you’re wondering what a Boeing 777-300ER looks like on the inside, a few years ago the American aviation enthusiast Luca Iaconi-Stewart built a detailed model of the plane from paper. The model includes details like bolts, hydraulic pipes and hinges, and features amenities such as food carts, galleys, and the hidden crew “rest module” that most passengers never get to see.

Middle East

British Airways Resumes Daily Flights to Abu Dhabi, After 4-Year hiatus

Photo: Wikipedia

British Airways made its way back to Abu Dhabi, landing at Zayed International Airport. Following a four-year break in service, both crew and passengers were greeted with enthusiasm.

In the summer of 2024, British Airways plans to launch a daily route, utilising a Boeing 787-9, from London Heathrow to Abu Dhabi. The new route enhances ties between the UAE and the UK and expands vast worldwide network, catering to passengers who may be visiting friends and family or travelling for business.

Arriving in Abu Dhabi at 08.30+1, flight BA073 to Abu Dhabi leaves London Heathrow at 22.25. Departing at 10.10 and landing at London Heathrow at 15.20 is the inbound flight (BA072).

The chief executive officer and managing director of Abu Dhabi Airports, Elena Sorlini, stated: “We are delighted to welcome British Airways to Zayed International Airport. Their daily schedule is expected to improve connectivity and stimulate travel and business.” Visitors may experience the dynamic capital of the United Arab Emirates like never before at our brand-new, award-winning, state-of-the-art terminal, where they will be welcomed with the best kind of Emirati hospitality.”

Flight schedule:

London Heathrow (LHR) to Zayed International (AUH)All times are local
Season	Flight number	Departing LHR	Arriving AUH	Flight number	Departing AUH	Arriving LHR
Summer ‘24	BA73	22:25	08:30+1	BA72	10:10	15:20
Winter ‘24	BA73	22:25	09:30+1	BA72	11:10	15:20

Airlines

EU Bans Turkish-based Southwind Airlines due to links with Russia

In a significant move reflecting the ongoing geopolitical tensions, the European Union (EU) has taken measures to prohibit Turkey’s Southwind Airlines from utilizing its airspace.

The decision, stemming from alleged connections with Russia, underscores the broader repercussions of Russia’s actions in Ukraine and the subsequent international sanctions imposed.

The ban, enforced on March 29, disrupts Southwind Airlines’ operations, initially leading to the cancellation of flights. The Finnish transport authority Traficom, headed by Jarkko Saarimäki, has been instrumental in elucidating the rationale behind the EU’s decision. Saarimäki’s assessment highlights a concerning lack of substantial ownership and effective control held by Turkish entities within Southwind Airlines.

Established in 2022 in Antalya, Turkey, Southwind Airlines had primarily focused on flights originating from Russia. However, scrutiny into its ownership structure has revealed apparent links to Russian stakeholders, prompting concerns over its allegiance and operational control. Saarimäki’s assertion of Russian influence over the airline’s affairs underscores the broader geopolitical implications of such connections.

The EU’s ban extends beyond merely restricting Southwind Airlines’ access to its airspace; it also encompasses prohibitions on takeoffs, landings, and overflights within EU territory. Consequently, the airline faces operational hurdles, impacting its routes not only to Finnish destinations like Helsinki but also to prominent German cities and potentially planned routes such as Zurich.

This development aligns with the stance adopted by other Western nations, including the United States, the United Kingdom, and Canada, which have implemented similar bans on Russian airlines. Such coordinated actions underscore the global resolve to hold Russia accountable for its aggressive actions in Ukraine and to mitigate potential security risks posed by entities with alleged ties to Russian interests.

Airlines

Indigo contributed 31 crores to India’s political party for election funds

In a recent disclosure, it has come to light that Rahul Bhatia, the promoter of IndiGo, along with companies under his InterGlobe Group, has made significant donations totaling Rs 56 crore to four political parties. Additionally, SpiceJet, led by Ajay Singh, has contributed Rs 70 lakh to the Aam Aadmi Party (AAP).

The data further reveals that InterGlobe Air Transport Ltd, a part of the InterGlobe Group, purchased 11 electoral bonds valued at Rs 1 crore each on May 10, 2019, amounting to a total of Rs 11 crore. Similarly, Interglobe Aviation, the parent company of IndiGo, acquired 5 electoral bonds worth Rs 1 crore each on October 23, 2023, totaling Rs 5 crore.

InterGlobe Real Estate Venture and InterGlobe Air Transport Ltd directed the lion’s share of their political contributions, totaling Rs 31 crore, to the Bharatiya Janata Party (BJP). Surprisingly, the second-largest recipient was the Trinamool Congress (TMC), receiving Rs 16.2 crore from Bhatia. Additionally, InterGlobe Aviation Ltd allocated Rs 5 crore to the Congress party, while Bhatia contributed Rs 3.8 crore to its ally, the Nationalist Congress Party (NCP).

Rahul Bhatia, individually, also made substantial contributions through electoral bonds, purchasing bonds worth Rs 20 crore. On April 7, 2021, a total of 29 electoral bonds were acquired, with 19 bonds valued at Rs 1 crore each and 10 bonds at Rs 10 lakh each, summing up to Rs 20 crore. When combined with the donations from IndiGo and its affiliated companies, the total contributions from the promoter and associated entities reach Rs 56 crore.

On the other hand, SpiceJet, once a prominent player in the Indian aviation industry, has seen a decline in its market position, currently ranking fifth in terms of market share. Despite this, the airline has engaged in political contributions, with donations made in three separate installments.