IAI Launches Boeing 777-300ERSF Freighter Conversions in Arizona

Israel Aerospace Industries has started Boeing 777-300ERSF passenger-to-freighter conversions in North America, with the first 777-300ER arriving at Ascent Aviation Services' expanded Pinal Air Park campus in Marana, Arizona.

The aircraft comes from the portfolio of lessor World Star Aviation. Ascent's Marana facility will now serve as the North American conversion site for IAI's 777-300ERSF programme, operating two parallel conversion lines under a long-term agreement with IAI.

The launch rests on hard capacity. Ascent has completed two purpose-built 90,000 sq ft widebody hangars at Marana to support IAI's global 777-300ERSF programme. The $70m investment triples hangar capacity at the facility and significantly expands Ascent's heavy maintenance and widebody modification capabilities.

What does this mean for cargo capacity?

IAI's 777-300ERSF is the world's first and only certified Boeing 777-300ER passenger-to-freighter conversion programme to date. That certification gives the platform a clear runway as operators seek freighter capacity without newbuild pricing.

The converted fleet is already earning its keep. In July, IAI's 777-300ERSF programme surpassed 20,000 cumulative flight hours since the first converted aircraft entered commercial service in September last year.

Guy Bar Lev, IAI's president and chief executive, said: "Our vision is to shape the future of aviation by turning engineering innovation into lasting value for our customers. Passenger-to-freighter conversions are a key part of that vision, extending the productive life of aircraft and helping airlines adapt to changing market needs."

He added that establishing a conversion presence in North America advances IAI's long-term strategy to strengthen its position in the global commercial aviation market.

Why Marana, and why now?

The site choice pairs IAI's certified conversion technology with Ascent's MRO infrastructure and widebody expertise. IAI said the facility expands global conversion capacity while giving customers greater flexibility and support in the North American market.

Yaacov Berkovitz, executive vice president and general manager of IAI Aviation Group, called the launch an important milestone for IAI's global conversion programme. "Together with Ascent Aviation Services, we are expanding production capacity and bringing our conversion capabilities closer to customers in the region," he said.

Berkovitz also credited World Star Aviation for its role in bringing the first aircraft to Marana, describing the three-way collaboration as support for cargo operators worldwide.

David Querio, chief executive of Ascent Aviation Services, said the aircraft marks the beginning of a long-term partnership with IAI and "the first of many" 777-300ERSF conversions in Marana. "As the demand for cargo conversions continues to grow across the aviation industry, Ascent is proud to be at the forefront of this expanding market," he said.

A lessor betting on the platform

World Star Aviation's decision to feed its aircraft into the programme signals lessor confidence in widebody P2F economics. Yoyo Allalouf, partner at World Star Aviation, said the firm chose IAI's programme because it believes it is "the strongest 777 P2F programme available at this most critical of times for 777 passenger to freight conversion production."

Allalouf added that Ascent's Marana facility provides the capacity and quality standards the lessor needs as it grows its freighter portfolio, framing the decision as managing value for investors across the cycle.

The relationship has deep roots. Garreth Slevin, partner at World Star Aviation, said the firm's history with IAI in widebody P2F programmes dates back to the 1990s and the Boeing 747-200 P2F programme. IAI's dominance in the widebody P2F space, demonstrated by its 747 and 767 programmes, underpinned the decision to choose IAI for the 777-300ERSF.

With two conversion lines running in Marana and the type already logging flight hours in commercial service, North American feedstock owners now have a domestic route into the only certified 777-300ER freighter conversion on the market.