6 days Ago By Luke Bodell
Boeing has converted several of its commercial aircraft series into freighters over the decades. The company's current Boeing Converted Freighter (BCF) program covers some of the manufacturer's best-known commercial aircraft families - the 737, 757 and 767. This is not to say these are the only Boeing aircraft being converted, as the company also works with third-parties on other models, such as the 777.
Through passenger-to-freighter ( P2F ) conversions, aging airframes that are no longer suitable for commercial travel are given a new lease of life flying cargo around the world. P2F conversions are also a highly cost-effective process for creating a freighter as opposed to manufacturing one from scratch, meaning airlines are able to acquire freighter aircraft at a lower cost. Taking a look at how passenger aircraft assume new lives transporting goods.
As a result, there has been a sharp rise in demand for P2F aircraft in recent years, with both Boeing and rival Airbus now offering several conversion programs for their commercial aircraft range. About Boeing's Converted Freighter (BCF) program Boeing has been converting passenger aircraft into freighters for more than four decades, and its conversion programs have continued to expand over the years. Given the added complexity of converting modern passenger aircraft, many P2F programs have relied on the expertise of third parties - as such, Boeing has partnered with companies like ST Engineering and Aeronautical Engineers (AEI) to perform these conversions.
With each company carrying out conversions differently, you'll find different names for P2F variants. For example, there are three 737 P2F variants - the 737-800BCF, 737-800SF, and 737-800BDSF - indicative of which company was involved in its conversion. What are the different Boeing converted freighters? The Boeing 'BCF' designation currently covers its 737-800 and 767-300 airframes, but there are a lot more converted Boeing freighters out there: Boeing 727 Boeing's first converted freighters came from its Boeing 727 family of aircraft, including the 727-100 and 727-200.
According to American Friendship , there were over 100 727-100 and 350 727-200 airframes converted into freighters at the end of their passenger service days. Boeing 737 The company's best-selling 737 narrowbodies have been a popular choice for cargo conversions, starting with the 737-300 and 737-400. With the majority of narrowbody freighters in service today previously flying as passenger aircraft, Boeing's 737 P2F range was always going to have enduring popularity.
The company's converted 737-800s are now available through three main providers - AEI (737-800SF), Boeing (737-800BCF) and Israel Aerospace Industries (737-800BDSF). Boeing announced its conversion program for the 737-800, called the 737-800BCF, in 2016, with the first deliveries taking place in 2018. According to ch-aviation data, over 180 737-800BCFs exist today , as well as around 50 737-800SFs and a handful of 737-800BDSFs.
Boeing has forecasted the need for up to 1,000 narrowbody freighter conversions by the mid-2030s. Boeing 737-800BCF Details Cargo Capacity 52,800 pounds (23,900 kg) Range 2,000 nautical miles Main Deck Cargo Space 5,000 cubic feet Pallet Positions 12 total: 11 standard pallets + 1 half-pallet Major operators of the Boeing 737-800BCF include Chinese freight carriers SF Airlines and YTO, European cargo operator ASL Airlines, and Sun Country. Boeing 747 Boeing launched its 747-400BCF program in 2004, redelivering the first converted airframe the following year to Cathay Pacific.
Given the industry-wide move away from quadjet aircraft in favor of more efficient twin engines, Boeing discontinued its 747-400BCF program in 2016, choosing instead to focus on the 737 and 767. Up to this point, the company had converted 79 747-400 airframes—split into 50 for the BCF and 29 for IAI's BDSF version—but would receive no new orders from 2012 onwards. However, there are still plenty of 747 converted freighters in service, with ch-aviation showing around 40 airframes active now and several more in maintenance.
Notable airlines operating the type include Asiana Airlines, Atlas Air, and Kallita Air. Boeing 757 With its longer airframe and range, the 757 has proven a popular choice for conversions and is ideal for mid-range sectors outside the 737's range. Boeing delivered its first converted 757-200 to DHL Aviation in 2001 and continues to see demand for Flying Pencil conversions - according to an Aviacionline report, 23 converted 757s were delivered in 2018 and the rate has stayed at double-digit deliveries in subsequent years.
Major operators of 757 converted freighters include launch customer DHL and fellow US-based cargo airlines FedEx and UPS. With production of the 757 ending in 2004 with 1,050 planes built, there are still over 200 passenger 757s in service with airlines today, most notably Delta Air Lines and United Airlines. Boeing 767 Boeing launched its 767-300BCF program in 2005 and the converted freighter continues to attract a lot of interest, offering operators a maximum payload of 53,000kg and a range of 5,775km.
The first Boeing 767-300BCF entered service with launch customer All Nippon Airways (ANA) in 2008, with ch-aviation data showing over 240 converted airframes today. In 2022, Boeing added a new conversion line in Guangzhou, China, to support the growing demand for 767 conversions. Demand for conversions was initially low due to delays with the Boeing 787 Dreamliner's entry-to-service, meaning airlines were operating the 767 as a passenger jet for longer than planned.
However, the 767-300BCF has now attracted over 100 orders, and IAI's version (the 767-300BDSF) has logged similar numbers. Boeing 777 The Boeing 777-300ERSF is the latest P2F conversion offered by Boeing and its partners IAI and GECAS. First announced in 2019, the first 777-300ERSF, also known as the "Big Twin", was converted for launch customer Kalitta Air in November 2023 and is currently completing certification flights ahead of its delivery.
IAI's "Big Twin" 777-300ERSF converted freighter will make its first airshow appearance at the upcoming Dubai Airshow next month. With the 777-300ER entering service in 2004, the program's timing is optimal as the first airframes are now starting to enter their end-of-service phases (for passenger operations, at least). IAI is the first company authorized to convert Boeing's 777 into a freighter.
Compared to the 777F, the 777-300ERSF can carry 25% more cargo at 101.6 tonnes payload, as well as consuming 20% less fuel than the 747 freighter..
