Summary
- Air cargo is a crucial part of global trade, representing 35% of the industry's value. Passenger-to-cargo conversions help meet the demand for freighters and extend the life of older aircraft.
- Converting a passenger aircraft to a freighter involves pre-conversion tests, gutting the interior, adding a new cargo door, making structural changes, and complying with different standards for freighters.
- Not all aircraft can be converted, as some lack the demand for conversion lines or are unsuitable as freighter aircraft. However, the COVID-19 pandemic has increased the demand for freighters and passenger-to-cargo conversions.
Air cargo is essential to the global aviation market, transporting over 65.6 million tonnes of goods annually. According to the International Air Transport Association (IATA), airline cargo transport represents about 35% of global trade by value but less than 1% by volume.
As such, the continuous growth of world trade, the need to transport special and time-sensitive goods, and the need to replace aging aircraft create a constant demand for freighters. One way to meet this demand is by converting older passenger aircraft to cargo aircraft. Let's take a look at the different stages of this process.
Why conversions happen
Converted aircraft begin their life flying passengers, but they can become outdated after some time. Passenger-to-cargo (P2F) conversions can add years to an aircraft's life, which is a massive deal since used aircraft are often much cheaper than newer models.
Moreover, a converted aircraft for a type that is out of production can allow an airline to grow its capacity without sacrificing fleet commonality. While the process depends on the aircraft and what sort of cargo it will transport, complete cargo conversions can give a plane up to 30% more cargo space while reducing fuel consumption per tonne of payload by about 20%.
Interested in cargo transport? Check out all our cargo news stories here
The process
The transformation of a passenger aircraft to a freighter primarily depends on four steps:
- Pre-conversion ground and flight tests
- Development of modified structures and interiors
- Qualification of new modified systems
- Post-conversion ground and flight tests
Upon arrival at a conversion facility, the aircraft undergoes various tests to ensure it is airworthy and ready for the transformation. Tests for data collection are conducted on all parts and systems of the plane.
Gutting the interior
Since the aircraft won't carry passengers anymore, the aircraft will need to be completely emptied. All the seats, overhead bins, carpets, consoles, galleys, and passenger lavatories will be removed from the aircraft. From here, the interior will be installed based on the airline's needs.
New cargo door
Since cargo doesn't need an emergency exit, the passenger doors are deactivated. However, the aircraft frame must also be fitted with a new entry for cargo loading. On most aircraft, this door is off to the side and opens up to reveal the large cargo compartment. Areas around the new door are reinforced to ensure the strength of the entire fuselage.
Structural changes
The aircraft will need to receive reinforced floors to handle the weight of heavy freight. Beams and posts help increase the durability and strength of the cargo bed. In addition, there are changes to aircraft fire detection systems, ventilation, and temperature control.
This is because freighters have different requirements than passenger aircraft and must comply with other standards. Some of these structural changes help balance the aircraft and keep it from tipping over. The aircraft windows are also sealed shut using aluminum panels.
Can all aircraft be converted?
Aircraft conversion lines exist for several aircraft and were built into the design of others. This means that some aircraft cannot be converted because there is insufficient demand to justify a conversion line. Furthermore, some aircraft, like the MD-90, are unsuitable freighter aircraft.
These aircraft usually lack sufficient range for cargo flights, are too old, and sometimes do not meet noise restrictions. As a result, there are no MD-90 lines, and even the MD-80 lines haven't been successful. On the other hand, some have been very successful, including the MD-11 and Boeing 767 freighters. Several A321s have also gone through P2F conversions.
Pandemic-induced demand
The outbreak of COVID-19 brought the global aviation industry to its knees, with almost all passenger aircraft grounded for a while. This also significantly reduced cargo capacity, as nearly 50% of the world's air freight traveled via widebody passenger aircraft. However, several airlines quickly adapted by operating cargo flights and transporting essential goods like food and vaccines.
The industry saw a surge in the demand for freighters and, in turn, passenger-to-cargo conversions. Since 2019, several conversion centers have been opened, with airlines receiving more and more converted freighters. A good example is the Ex-Condor Boeing 767 set to take a new life as a freighter in China. The process has many steps and requires significant modifications, but it can be incredibly beneficial to airlines and lessors.
How important do you think P2F conversions are for airlines? Please drop us a comment below!