FAA Gives the Green Light! 777s Are Now Being Converted into Cargo Aircraft
The FAA has granted Mammoth Freighters the authority to convert Boeing 777-200 passenger aircraft into cargo planes. Qatar Airways, DHL and Ethiopian Airlines have joined the project.
FAA Green Light for 777 Cargo Conversion
The U.S. regulator, the Federal Aviation Administration, has granted newly established aviation company Mammoth Freighters LLC the authority to convert Boeing 777-200 passenger aircraft into cargo aircraft capable of carrying containers on the main deck.
This development paves the way for the 777-200 model to enter commercial service for the first time as a converted freighter.
Major Airlines Join the Project
As part of the conversion programme:
- Qatar Airways
- DHL Express
- Ethiopian Airlines
Global players such as these have collaborated with Mammoth Freighters.
Under agreements carried out through Texas-based Jetran, Ethiopian Airlines has included two 777-200 aircraft in the programme for conversion.
Conversion Process and Technical Features
The conversion system developed by Mammoth Freighters includes critical modifications such as:
- Large cargo door
- Reinforced floor
- 9G safety barrier
- Advanced temperature control
- Pallet transport systems
While the conversion of a single aircraft takes on average 6 to 8 months, this duration is expected to shorten as the process matures.
Rising Demand for Cargo Aircraft
In the global aviation sector:
- The approaching retirement of older aircraft
- Delays in the production of new cargo aircraft
- Increasing logistics demand driven by e-commerce have boosted the need for wide-body freighters.
In particular, Boeing’s plan to end 767 freighter production in 2027 makes conversion projects even more critical.
Alternative Programmes Also Underway
Similar conversion efforts are also being carried out by Israel Aerospace Industries. The company has received approval for a conversion kit for the 777-300 model, while Kalitta Air and Challenge Group have already started operating these aircraft.
Production and Delivery Plan
Mammoth Freighters continues its operations with:
- A main production line in Fort Worth, Texas
- An additional facility in Manchester, UK
Initial deliveries will be made to:
- Qatar Airways
- Followed by DHL Express
DHL aircraft are planned to be used in operations based at East Midlands Airport in the UK.
Certification Process Took Longer Than Expected
The programme’s certification process progressed with delays due to:
- Post-Covid supply chain issues
- Increased safety inspections by the FAA
- Stricter regulations following the Boeing 737 MAX accidents
The company is also expected to receive approvals from European and Qatari authorities in the coming period.
Performance and Capacity Advantage
The converted 777-200 freighter offers:
- 116-ton payload capacity
- 4,900 nautical miles range
- 18% lower fuel consumption compared to the Boeing 747-400
Thanks to its large volume, it stands out as an ideal solution especially for e-commerce and light cargo transportation.
