{"id":89763,"date":"2025-10-22T00:00:00","date_gmt":"2025-10-22T00:00:00","guid":{"rendered":"https:\/\/enterpriseam.com\/logistics\/2025\/10\/22\/air-freighters-are-facing-a-jet-supply-crunch-here-is-how-mammoth-freighters-is-working-to-fill-the-gap\/"},"modified":"2025-10-22T00:00:00","modified_gmt":"2025-10-22T00:00:00","slug":"air-freighters-are-facing-a-jet-supply-crunch-here-is-how-mammoth-freighters-is-working-to-fill-the-gap","status":"publish","type":"post","link":"https:\/\/enterpriseam.com\/logistics\/2025\/10\/22\/air-freighters-are-facing-a-jet-supply-crunch-here-is-how-mammoth-freighters-is-working-to-fill-the-gap\/","title":{"rendered":"Air freighters are facing a jet supply crunch \u2014 Here is how Mammoth Freighters is working to fill the gap"},"content":{"rendered":"

Air freighters are bracing for a major jet supply crunch as demand for air <\/strong>cargo grows at a much faster pace than added capacity.<\/strong> Global air cargo volumes were up 6% y-o-y in July 2025, while capacity dropped 2% y-o-y in the same month, according to a DHL report seen by EnterpriseAM. Looking ahead, this crunch is expected to become more acute, as some 24% of the current freighter fleet \u2014 in terms of capacity \u2014 is forecasted to be retired out of service by 2033, DHL found. <\/p>\n

Against this industry-wide headwind, airlines are steadily turning to retrofits. <\/strong>Demand for retrofits is going up<\/a> as airlines work to ramp up capacity amid industry-wide delivery delays. Emirates enacted a USD 5 bn retrofitting plan aimed at extending the operational life of existing jets as it waits for delayed deliveries earlier this year.<\/p>\n

And the Texas-based <\/strong>Mammoth Freighters<\/a><\/strong> is working hard to seize on this moment amid rising demand for retrofits. <\/strong>A Boeing licensee, Mammoth Freighters launched operations in 2020 and specializes in retrofitting Boeing\u2019s flagship passenger 777 model \u2014 including the 200 Long Range and 300 Extended Range variants \u2014 to be cargo-ready. <\/p>\n

Why retrofits? <\/strong>Retrofitted jets are a very good \u201cgap filler,\u201d Mammoth Freighters Sales and Marketing VP Brian McCarthy told EnterpriseAM. \u201cIf you can\u2019t get new airplanes and you want to stay with the Boeing platform\u2026. then [airlines] need a gap filler,\u201d McCarthy told us. Mammoth Freighters\u2019 passenger-to-freighter (P2F) models provide operators a reliable \u201cseven to ten year gap filler until Boeing can deliver enough passenger aircraft and freighters,\u201d he added.<\/p>\n

Pricing can be a plus, too: <\/strong>There is quite a substantial differential in the pricing of the aircraft, with the retrofitted 777-200LR costing \u201cclose to USD 80 mn to USD 90 mn lower than a brand new built freighter,\u201d McCarthy told us. <\/p>\n

REMEMBER- Regional demand is booming:<\/strong> The Middle East commercial aviation market is forecasted to be driven by growing air travel demand, budget carriers, and significant aircraft orders. Overall, the region\u2019s fleet is expected to increase by 5.1% annually, bolstered primarily by narrowbodies, according to an Oliver Wyman report (pdf)<\/a>.<\/p>\n

The 777 model is preferred because of its proven durability and longevity, capable of performing reliably<\/strong> for many more flight years even after 10-15 years of service, McCarthy explained. The 777-300ER model<\/a> can carry 819 cbm in volume with a max payload of around 98 tons, while the 777-200ER model can carry more weight at a maximum payload of up to 106 tons but at a smaller volume of 650 cbm.<\/p>\n

Boeing is all in: <\/strong>To support customers facing delivery snags, Boeing is supporting the P2F model, McCarthy said. \u201cBoeing has been more and more helpful in making sure that their customers are accommodated,\u201d and players like Mammoth help provide additional cargo capacity until Boeing can fulfill their orderbooks, he added. <\/p>\n


REFRESHER-<\/strong> Boeing pushed back delivery dates<\/a> of its awaited 777x aircraft last year, with first deliveries forecasted for 2026. Delivery delays have been exacerbated over the last two years by engine storages<\/a>, machinists\u2019 strikes<\/a>, and production cuts<\/a> caused by quality and safety concerns.<\/p>\n

Qatar Airways is set to be the <\/strong>first uptaker<\/a><\/strong> of Mammoth Freighter\u2019s 777-200ER P2F models<\/strong>, after it commissioned five jets earlier this year through US-based leasing firm Jetran. Qatar Airways is getting \u201cthe first two aircrafts coming off of our production line, as soon as they are certified,\u201d McCarthy told us. \u201cWe are closing in on certification, right now, and finishing all our final flight tests,\u201d he added.<\/p>\n

A canon event<\/strong>: <\/strong>Mammoth Freighters believes that Qatar\u2019s 777-Max deliveries will act as a \u201ctriggering event\u201d for more orders, but the company said it will remain focused on quality and remaining on schedule. \u201cWe'd rather make sure we focus on the certification tasks and support and deliver what we've already promised,\u201d McCarthy added.<\/p>\n

P2F is an attractive model for leasing firms: <\/strong>Conversions into freighters is more practical for leasing firms compared to passenger jets. When a major carrier like Emirates or Qatar returns an aircraft to the lessor, the plane is highly unlikely to find another passenger airline, McCarthy said. This is because the retrofitted aircraft is fully branded \u2014 with operational standards and cabin configuration tailored specifically to the initial airline \u2014 making re-entry into service with a different carrier exceptionally complex and difficult, he added. <\/p>\n

P2Fs conversions also take the lead price-wise: <\/strong>\u201cOn a passenger plane, the residual value normally just falls and goes all the way to zero over some span of time, but on a freighter it goes down to a certain value and then stays there; it doesn\u2019t keep falling but levels off over time.\u201d That means that while it costs more to turn a jet into a freighter, long-term operational durability makes passenger-to-freighter jet retrofits (P2F) financially viable.<\/p>\n

More retrofits also mean a better business outlook for maintenance, repair, and overhaul (MRO) services providers<\/strong>, as the prolonged lifespan of aging carriers means there\u2019s a bigger need for regular maintenance services and more modifications and installations of spare parts, he added. <\/p>\n

The MRO market is already heating up:<\/strong> Global MRO market size reached USD 114 bn in 2024, growing by 7.2% during the post-pandemic period, according to data from consulting outfit Oliver Wyman. The MRO market is expected to grow annually by a steady average of 2.7% to reach USD 156 bn in 2035.<\/p>\n

But retrofitters like Mammoth also have to navigate supply chain snags. <\/strong>To hedge against any supply disruptions, the company began bulk ordering key parts two to three years ago. \u201cWe were buying 10 chip sets at a time, even though we didn\u2019t really need them yet,\u201d loading up on inventory at a great expense to \u201cinsulate ourselves because we were watching the whole industry suffer.\u201d Some 99% of Mammoth Freighters\u2019 materials are also bought locally in the United States at present, in a bid to maintain a more centralized supply chain than its counterparts in the industry. <\/p>\n

They aren\u2019t alone:<\/strong> Etihad Airways is weighing bulk buying<\/a> aircraft parts and storing them in local warehouses for on-demand access \u2014 in a bid to sidestep supply chain gridlocks from planemakers. The bulk purchases are aimed at lowering downtime for jets undergoing retrofits in a bid to minimize network disruptions as the Abu Dhabi-based carrier rolls out a USD 1 bn retrofit program<\/a> for its existing fleet.<\/p>\n

Looking forward: <\/strong>The company is aiming for a production capacity of 16 or 18 airplanes per year, with some seven airplanes in the works right now. <\/p>\n","protected":false},"excerpt":{"rendered":"

Demand for retrofits is going up as airlines work to ramp up capacity amid industry-wide delivery delays<\/p>\n","protected":false},"author":1,"featured_media":89764,"comment_status":"","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"newspack_ads_suppress_ads":false,"newspack_popups_has_disabled_popups":false,"newspack_sponsor_sponsorship_scope":"","newspack_sponsor_native_byline_display":"inherit","newspack_sponsor_native_category_display":"inherit","newspack_sponsor_underwriter_style":"inherit","newspack_sponsor_underwriter_placement":"inherit","ep_exclude_from_search":false,"_primary_brand":0,"newspack_featured_image_position":"","newspack_post_subtitle":"","newspack_article_summary_title":"Overview:","newspack_article_summary":"","newspack_hide_updated_date":false,"newspack_show_updated_date":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[459],"tags":[145,122,153,247,696,124],"brand":[],"newspack_spnsrs_tax":[],"class_list":["post-89763","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-spotlight","tag-aviation","tag-cargo","tag-qatar","tag-qatar-airways","tag-spotlight","tag-supply-chains","wpautop","entry"],"acf":{"mongo_id":"5f1f3ed3-d33f-484c-9bc2-615ff384d5b9","order":"6","is_powered_by":false,"story_type":"1","photo_url":"https:\/\/ent.news\/2025\/10\/1095.jpg","photo_position":"above","homepage_title":"","full_issue_title":"Air 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