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www.avitrader.com
August 2021
Cargo Conversions
Composite
Special Issue Repairs
Bringing new
techniques to
the market
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3
Editor‘s Page
P2F conversions accelerate as
Recently, e-commerce has
triggered strong demand for
demand grows
all-cargo aircraft.
Photo: ATRAN Airlines
A
s the aviation industry continues to evolve, the air cargo sector is at the forefront of market
recovery. Since the peak of the Covid crisis in May last year, some 200 aircraft have joined the
global freighter fleet with newly converted Boeing 737-800s and A321s making up a significant
chunk of recent conversions, so clearly, the demand to convert aircraft from passenger to cargo has
grown significantly. Boeing forecasts 1,500 freighter conversions will be needed over the next 20 years to
meet growing demand.
In this issue we bring to you a special supplement that brings together the latest developments and
initiatives in the aircraft freighter conversions sector. Indeed the covid crisis and subsequent growth in
demand for express and e-commerce have given the air freight sector a boost, in particular for all-cargo
aircraft capacity.
An interesting report recently released by aviation experts at IBA indicates that older aircraft
have borne the brunt of the Covid19 pandemic’s impact on values. Whilst the aircraft’s suitability for
passenger to freighter ‘P2F’ conversion has given slight cause for optimism, IBA expects a significant
number of airframes to exit the fleets of key operators such as Cathay Pacific, Emirates and Qatar in the
near future.
The big announcement coming out of the 777-300 is of course the start of IAI's structural
modification phase in the conversion of the first Boeing 777-300ERSF, in partnership with GECAS, so we
have followed that development closely in this edition. And with the release of our first freighter
conversion supplement we would like to thank all the participants and a special appreciation
to our advertisers for supporting the initiative: Aeronautical Engineers Inc (AEI), Precision
Aircraft Solutions, GA Telesis, Pratt & Whitney, Ascent Aviation Services and IAI.
Please check out the solutions they offer to the freighter market.
Feel free to contact me if you would be interested in participating in future special
reports looking in depth at your sector of the market.
Keith Mwanalushi
EDITOR
AviTrader MRO - August 2021
Contents
www.avitrader.com
August 2021
Composite
14
Cargo Conversions
Special Issue Repairs
Composite Repairs
Bringing new
techniques to
the market
Cover image:
British Airways
3
Publisher
Peter Jorssen Editor‘s Page
p.jorssen@avitrader.com
5
Editor
Keith Mwanalushi
5 Industry Briefs
keith@aeropublications.co.uk
VP Sales & Business Development 10 News Analysis
(Advertising) ASQS Ensuring a quality mindset
Tamar Jorssen
tamar.jorssen@avitrader.com
10
Phone: +1 (778) 213 8543
12 News Analysis
Graphic Designer Digital Flight: Positive climb as digital flight takes off
Volker Dannenmann,
12
volker@dannenmann.com
Sales & Marketing Manager
14 Composite Repairs
Malte Tamm How are they shaping up?
malte.tamm@avitrader.com
Managing Editor
17 Freighter Conversions
Heike Tamm
heike.tamm@avitrader.com 17 Special Supplement
Published monthly by
AviTrader Publications Corp.
Suite 305, South Tower
34 Company Spotlight
5811 Cooney Road Aero Norway
Richmond, British Columbia
34
36
V6X 3M1
Canada Industry Interview
Tel: +1 (424) 644-6996
Norbert Marx – General Manager, GAMECO
www.avitrader.com
36 39 People on the Move
INDUSTRY BRIEFS 5
Flyadeal takes off with the 1,000th aircraft covered by Airbus’ Flight Hour Services
flyadeal, the low-cost Jeddah-based
airline owned by Saudi Arabian
Airlines, signed a long-term Flight
Hour Services (FHS) agreement to
support its A320 fleet.
The agreement includes the
1,000th aircraft supported by Airbus
Flight Hour Services. The carrier will
benefit from integrated material
services including spare pool access,
on-site-stock at the main base and
components engineering and repairs.
Through the FHS contract, Airbus will
guarantee spare parts availability,
contributing to securing aircraft
technical performance.
Mikail Houari, President of Airbus
Africa & Middle East, said: “Signing
this agreement with flyadeal is an
important milestone; it is the 1st flyadeal has signed a long term FHS agreement to support its A320 fleet Photo: Airbus
FHS contract in Saudi Arabia and the
biggest Airbus aircraft fleet to be covered by FHS”.
“We are proud of our partnership with flyadeal and look forward to continuing working together. This agreement reaffirms
our commitment to supporting Saudi Arabia’s aviation sector”, Houari added.
Airbus has finalised 11 Flight Hour Services contracts with operators worldwide over the last six months. The latest contract
agreements demonstrate the continued interest in Airbus’s integrated maintenance service, proving more relevant than ever in
post-crisis times when airlines need to carefully monitor their costs and contain investments.
Honeywell and Lufthansa Technik sign MRO agreement for components in CFM LEAP
series engines
Honeywell and Lufthansa Technik have signed an extensive
collaboration agreement for the maintenance of Honeywell
components installed on CFM International’s LEAP series engines
which are used in Airbus A320neo-family, Boeing 737 MAX,
and COMAC C919 aircraft. Under this agreement, Lufthansa
Technik will develop Maintenance, Repair and Overhaul (MRO)
capabilities for the Honeywell components. By this, the company
will be able to offer improved and OEM-certified aftermarket
services, with increased component reliability and reduced
operator life-cycle costs. Lufthansa Technik and Honeywell have
enjoyed a long standing, collaborative relationship including
Lufthansa Technik as the licensed component repair center and
exclusive global asset provider for all Honeywell products on
Airbus A350 aircraft. Moreover, Lufthansa Technik brings a new
level of predictive health management expertise to airlines,
with the inclusion of Honeywell Forge analytics on Lufthansa
LEAP engine Photo: LHT Technik’s AVIATAR platform.
AviTrader MRO - August 2021
INDUSTRY BRIEFS 6
Magnetic MRO and
Aerospheres have signed Causeway Aero Group gets repeat order for Pitch
Chemical Consignment PF3000 seats
Agreement Causeway Aero
Group has received
Magnetic MRO, a Total Technical Care
a repeat order from
and Asset Management organization,
Israir Airlines for a
has signed a chemical consignment
shipset of its Pitch
agreement with Aerospheres U.K.,
PF3000 light-weight
a London-based leader in real-time
economy seat. Israir,
distribution of chemicals, paints,
the Israel-based
adhesives, sealants, and composites
travel group, became
in support of commercial airline MRO
launch customer
operations worldwide. Aeropsheres
for the PF3000 in
U.K. has been a long-term partner of
early 2018, fitting
Magnetic MRO, supplying chemicals and
it to three Airbus
adhesives to the company, but with the
A320 aircraft, each
new chemical consignment agreement,
with 150 seats in a Israir Pitch PF300 light-weight economy seats Photo: Causeway Aero
the partnership extends. It now covers
3+3 configuration
supply chemicals and adhesives required
at 30in pitch. The aircraft are operated on scheduled and charter flights to various
for maintenance tasks as Aerospheres
destinations in Europe and Israel. The new order is for the fifth A320 to join the
own materials will be stored in Tallinn,
fleet, which has just completed a lease transition check and cabin reconfiguration
Magnetic MRO stock, starting from
at the BCT Aviation MRO facility in Shannon, Republic of Ireland.
August 2021.
StandardAero to provide Lufthansa CityLine with GE CF34-8C engine support
Lufthansa CityLine is a wholly
owned subsidiary of Lufthansa, one
of the world’s leading airline groups,
operating feeder flights from hubs at
Frankfurt Airport and Munich Airport.
StandardAero was first appointed as a
GE Aviation Authorized Service Provider
(ASP) for the CF34-3 and CF34-8 in 2001,
and in 2013 was named by GE as the
first independent TRUEngine authorized
MRO provider for the CF34. In 2020,
the company celebrated its milestone
3,000th CF34 engine workscope.
Commenting on the agreement
for Lufthansa CityLine, Michael
Lariviere, Vice President Technical
StandardAero will support Lufthansa CityLine with a range of CF34-8C services Photo: Lufthansa Fleet Management said: “Reliable
operations are at the center of our
German airline Lufthansa CityLine has Lufthansa CityLine with a range of business, and for that we need reliable
selected StandardAero to provide CF34-8C services from its overhaul facility partners. StandardAero has proven to
support for the GE Aviation CF34-8C in Winnipeg, MB, Canada. StandardAero be a professional and committed service
turbofan engines powering its fleet of will also be qualifying its European provider to us in the past. That’s why
MHI RJ Aviation (formerly Bombardier) field service team based in Rijen, the we absolutely look forward to working
CRJ900 regional jets. Netherlands to support the CF34, thereby with the great team of StandardAero
Under the exclusive seven-year assuring Lufthansa CityLine of responsive in the coming years even closer than
agreement, StandardAero will support local airside assistance. before.”
AviTrader MRO - August 2021
INDUSTRY BRIEFS 7
International cargo operator
upgrades B767 Flight Decks Spirit Aeronautics adds Texas location
with Thomas Global’s Spirit Aeronautics,
TFD-7000 series LCD displays a leading avionics
solutions provider
A major international cargo operator for business, special
has selected Thomas Global’s TFD-7076 missions, and
LCD displays from the TFD-7000 series military aircraft,
to replace the legacy Cathode Ray Tube has announced its
(CRT) Engine Indicating & Crew Alerting expansion in a key
System (EICAS) displays remaining in location at Meachum
the operator’s Boeing 767 flight decks, International Airport
which had previously been retrofitted (KFTW). Serving the
by Innovative Solutions & Support Inc. Dallas/Ft. Worth
(IS&S). The TFD-7000 Series is a drop-in metroplex, Spirit
replacement for all legacy CRT displays Aeronautics will
in Boeing 767, 757 and 737 flight decks. operate from Baker
Baker Aviation hangar Photo: Spirit Aeronautics
It also provides a standalone LCD Aviation’s new
solution for the CRT-based EICAS displays 70,000 ft² hangar
remaining in B757/767s installed with facilities providing avionics modifications and flight line support for local aircraft
the IS&S flat-panel retrofit. The TFD- operators. Baker Aviation has recently constructed aircraft hangar facilities at KFTW
7000 Series captures all the benefits for large business class aircraft to elevate its growing repair station and charter
of LCD technology, delivers dramatic operations. This new expansion created an opportunity for partnership with Spirit
operating efficiency and life-cycle cost Aeronautics to provide leading-edge avionics installation and complex modifications
improvements, and a growth platform in partnership with Baker’s repair station business. “We saw an increasing need to
for emerging airspace requirements. The provide high-level avionics services in the Dallas/Ft. Worth area,” stated Rick Ochs,
drop-in design avoids major flight deck CEO of Spirit Aeronautics, “Baker Aviation has designed state-of-the-art facilities
modifications, significantly reducing with the capability for our team to continue providing the same level of avionics
associated aircraft downtime and crew services and support as we’ve done for more than 20 years at our OH location”.
retraining costs.
Rolls-Royce reports good start to the year with improving cash flow and profits
Rolls-Royce Group’s underlying revenue from continuing large-engine major shop visits were completed, and 100 large
operations for the first half year of 2021 was £5.2 billion, engines were delivered. The Group has already seen a return
down 2%, which reflected a more balanced contribution to 2019 levels of flying activity for its business aviation engines
from the business units compared with the same prior-year and for large engines operated on domestic flying routes.
period. It included a positive £160 million Civil Aerospace LTSA However, international travel is recovering more gradually,
revenue catch-up compared with a £(866) million negative hindered by global variation in vaccination rates and ongoing
revenue catch-up in the first half of 2020. Group underlying travel restrictions. The Group’s liquidity position was strong with
operating profit from continuing operations of £307 million £7.5 billion of liquidity including £3.0 billion in cash at the end
included significant cost savings from the restructuring of the half year after repaying the 2021 €750 million loan notes
program, primarily in Civil Aerospace, and favorable timing and the £300 million Covid Corporate Financing Facility (CCFF)
and mix of activity in Defense and Power Systems. The prior loan in the first half. Net debt (before leases) was £(3.1) billion at
period comparative underlying loss of £(1.6) billion included the period end. The Group signed an extension to the 2022 £1
£(1.2) billion of one-off charges mostly related to the impact of billion unused loan facility to 2024, consequently it has no debt
COVID-19 on Civil Aerospace. In Civil Aerospace, Rolls-Royce’s maturities before 2024 (excluding ITP Aero). Free cash outflow of
first-half operational performance saw an overall improvement £(1.2) billion represented a significant improvement on the same
with a recovery in business aviation and domestic large-engine prior-year period of £(2.9) billion, which included a £(1.1) billion
flying activity together with substantial cost benefits from its negative impact from the cessation of invoice factoring. The £0.6
fundamental restructuring program, which is reducing the size billion underlying improvement reflected good progress on cost
of its cost base by around a third. Large engine LTSA flying hours reduction, stronger operating performance, and reduced capital
were 43% of the 2019 level, up from the 34% in H2 2020; 92 expenditure. (£1.00 = US$1.39 at time of publication.)
AviTrader MRO - August 2021
INDUSTRY BRIEFS 8
Aergo Capital acquires A330s in sale and leaseback transaction with Iberia
Two A330s are subject to long-term leases with Iberia Photo: Iberia
Aergo Capital Limited has completed the sale and leaseback proactive and fully supportive in this transaction, resulting in
of two widebody aircraft with Iberia. The transaction includes a smooth closing process. We are looking forward to further
the sale and leaseback of two Airbus A330-200 aircraft, developing our relationship with the Group and Iberia"
bearing manufacturers serial numbers 1864 and 1882. Both Justin Bradburn, Principal Carval Investors. "We are
aircraft are subject to long-term leases with Iberia. delighted to close this transaction and broaden the growing
Fred Browne, Chief Executive Officer of Aergo, relationship with Iberia and the IAG group". Mal Murphy, IAG
commented: "We are extremely happy to partner with Iberia Head of Fleet Investments, commented that IAG was very
and further strengthen our relationship with IAG by adding pleased to add Aergo to the IAG panel of trusted lessors with
one more carrier to the portfolio. We found Iberia to be this transaction.
Oriental Air Bridge signs with TRAX
Muirhead Avionics achieves accreditation to
eMRO
the Joint Supply Chain Register
Nagasaki-based Oriental Air Bridge has inked a deal
Muirhead Avionics, a business unit of AMETEK MRO, has
with TRAX to implement the web-based eMRO system
successfully renewed its JOSCAR accreditation as Muirhead
to manage maintenance activities on its fleet of
Aerospace Ltd. JOSCAR (the Joint Supply Chain Accreditation
Bombardier Dash 8 aircraft.
Register) is a collaborative tool used by the aerospace, defence,
The airline operates charter flights throughout
and security industry to act as a single repository for pre-
southern Japan in addition to scheduled services
qualification and compliance information. Using JOSCAR can
between Nagasaki and remote islands and between
determine if a supplier is fit for business.
Fukuoka and several destinations. The airline has
“Pre-qualification and full compliance on the Hellios
been flying since 1961 – originally known as Nagasaki
Information JOSCAR supplier accreditation register streamlines
Airways having been renamed as Oriental Air Bridge
work-flow agreements and ensures the sustainability of our
(ORC) in 2001.
long-term customer relationships. Muirhead Avionics’ ongoing
Implementing the eMRO cloud solution with its
commitment to our customers in the aerospace, defence,
leading-edge technology will bring many advantages
and security industries is underpinned by this reassuring
to ORC. Users can have maximum mobility while
accreditation,” said Steve Wells, Managing Director and Divisional
accessing required documentation and electronic data,
Vice President of Muirhead Avionics.
viewing assigned maintenance tasks, receiving real-
Muirhead Avionics is a major supplier to many fixed and rotary
time updates on planned and completed work, tapping
wing operators worldwide with capabilities covering navigation,
into integrated materials modules, and an overall
communication, flight recorders, cockpit voice recorders,
increase in lowered costs, enhanced productivity, and
instrumentation, and test equipment.
efficiency.
AviTrader MRO - August 2021
SIMPLICITY
FOR THE
WIN
WHEELS AND BRAKES
IT’S THAT SIMPLE
TPAEROSPACE.COM
10
NEWS ANALYSIS
Ensuring a
quality
mindset
Icelandair was looking to streamline
its operational safety and quality
management and ASQS GmbH
subsequently won the contract
to modernise the airline’s safety
approach. Keith Mwanalushi
speaks to its Chief Executive
Günther Schindl.
I
n June, Vienna-based ASQS
announced a new contract
with Icelandair for integrated,
web-based aviation quality and
safety management software
IQSMS as an auditing, reporting
and safety management tool for
its international and domestic
flight operations.
The introduction of the
system is taking place in
separate phases and has
already started with the
implementation process of the
IQSMS Quality Management
Module. “Basically, the
implementation process varies
from customer to customer,”
Günther Schindl, Chief ASQS CEO Günther Schindl
Photo: ASQS
Executive at ASQS explains to
AviTrader MRO. He says the
process depends on what has
been contractually agreed or usually starts with an implementation the software solution in the best and most
how the customer envisions kick-off meeting to outline the project efficient way, notes Schindl. “Once the
the process. “Normally, one scope, followed by the joint elaboration of project is completed and our customers
of our project managers, who the project plan, according to which the have launched the system and gone live,
is the single point of contact configuration of the commissioned IQSMS our committed customer support service
for new customers on the modules is carried out in various meetings.” team takes over and assists IQSMS users
ASQS side, accompanies the Certainly, ASQS offers dedicated IQSMS almost 24 hours during the weekdays.”
clients through the entire training for the selected modules to equip By implementing IQSMS, Icelandair joins
implementation process. This operators with the necessary ability to use the steadily growing global ASQS family of
AviTrader MRO - August 2021NEWS ANALYSIS 11
“
currently more than 220 small to large In general, if you have an AOC, quality and safety
airlines, business jet and helicopter
operators, maintenance organisations,
management remains essential for operations, which
and airports. With Icelandair, the is why there was hardly any noticeable changes in
Austrian quality and safety management the market in this area and, luckily, we got through
”
software provider has now welcomed its
the crisis comparatively well.
second customer in Iceland.
Schindl agrees that the operational Günther Schindl, ASQS
and monetary impact of Covid-19
has been tremendous for the aviation
industry considering that safety and
quality management is essential for luckily, we got through the crisis ensure the flow of information between
aviation operators. He believes that comparatively well.” different software applications and
this has not altered during the crisis. For ASQS as a company, it was third-party solutions. Especially in the
On the contrary especially in the important to accompany and support quality management area, the system
Management of Change operators in the best feasible way. must be able to fulfil diverse needs on
(MoC) area where “We found very individual solutions different fronts, for example, it must be
risk analyses and were then able to go through simple to use, but comprehensive and
are needed in the crisis together with our clients. powerful in its functionality.”
times of strong What the Corona pandemic showed The industry
operational very clearly, however, was that has clearly
changes. “In automation, as we offer it with been
many companies, our IQSMS solution, is moving
the MoC was also becoming towards
heavily challenged increasingly a digital,
by downsizing
measures and the
management of the
The introduction of the system at Icelandair
associated is taking place in separate phases.
Photo: Boeing
changes in the
company,” he highlights.
Now that the market is recovering, important in the safety and
the relaunch of flight operations quality sector, especially in times of connected world, an evolution that is
must of course also be accompanied crisis, but also in general,” Schindl reflected in the advancing digitalisation
appropriately. “In this respect, our observes. in the aviation industry. Schindl stresses
product IQSMS has been in demand Speaking further on innovation and that the linking of different software
during the crisis, especially in the technology this sector too is evolving solutions and the uncomplicated
realm of the MoC, and supported our and Schindl says Big Data analyses sharing of data and information is
clients well in adapting to what is the are becoming more important as are becoming increasingly important
new normal. In general, if you have an interfaces (APIs) between software in the safety and quality assurance
AOC, quality and safety management solutions. “For this reason, we have sector, as collected data can be
remains essential for operations, which increasingly focused our developments quickly transmitted to the responsible
is why there was hardly any noticeable in recent years on offering our persons and further processed in other
changes in the market in this area and, customers a wide range of APIs to applications.
AviTrader MRO - August 2021NEWS ANALYSIS
Positive climb 12
as digital flight
takes off
Airlines are seeking digital solutions to overcome challenges in the industry.
Photo: Lufthansa Technik
Digital Flight, a new hub for digital technology in
aerospace launched in July, Keith Mwanalushi met with
the Founder Craig Skilton to discuss the importance
and benefits of the platform to the industry.
R
ight across the industry, we are “Now more than ever, businesses
seeing growing interest in the are seeking digital solutions and the
uptake for digital solutions in benefits will help overcome the challenges
support of aircraft maintenance and we face in the industry,” Digital Flight
aftermarket activities and recent industry Founder Craig Skilton tells this publication
news from several industry players shows exclusively. “We’ve seen that you can
examples of the growing pursuit for operate quicker, more efficiently and
digital solutions. often more accurately with the help of Craig Skilton, Founder, Digital Flight
Recently, Digital Flight officially technology but knowing what the options
launched its new online hub designed to are and more importantly finding a enthusiastic about digital advancement
promote the digital technology available dependable provider has been incredibly in aerospace, particularly in parts
to the aerospace market. The platform difficult – we have been there.” Skilton trading and MRO but we knew there was
was launched in July 2021 with an initial says Digital Flight helps to prepare for something missing. There’s not enough
showcase of over fifty companies covering that journey ahead, giving the seeker all awareness of all the technology that is
all aspects of the aerospace industry from the available options and providing them available in the market and finding the
aircraft maintenance, component repair, with guidance to make the right choice. right solution is not easy, which means
blockchain, flight operations, process Skilton stresses that Digital Flight is change up until now has been slower and
automation and ecommerce providers. serious about change, aiming to influence much harder than expected. That is why
Some of the solutions featured on the the adoption rate of digital in the we have created Digital Flight, to connect
platform include AJW eventory, skyselect, industry, through increased awareness, those seeking a solution to the providers
WinAir ROAM and others. accessibility, and community. “We are of them.”
AviTrader MRO - August 2021NEWS ANALYSIS 13
“
technology where there takes time for new habits to form, it won’t
We are enthusiastic about digital are great benefits for be overnight but Digital Flight will be
advancement in aerospace, part traceability and supporting that adoption process.”
aircraft maintenance Looking at technology and data
particularly in parts trading and records. Overall, we are strategies post the Covid crisis, its worth
MRO but we knew there was now questioning any noting that the aviation sector has taken
”
something missing. manual task or pain point a large hit through the pandemic, with
and exploring if there flying hours significantly reduced. The
Craig Skilton, Digital Flight is a solution via digital entire aftermarket supply chain has faced
technology,” Skilton the same reductions in work inflow.
highlights. Interesting, while in conversation with
Several airlines and MROs are looking When discussing the biggest an industry executive recently, they
to accelerate digital initiatives, clearly challenges with the adoption rate for noted that more aviation businesses
and at Digital Flight they are observing digital in MRO and parts trading, Skilton are partnering or creating a separate
more airlines partnering with innovative reminds that most of the parts trading digital innovation hub, a solution-
solutions, which is encouraging for the and MRO is still conducted using email driven incubator with the goal of scaling
industry. “Others are forming teams because that has been the standard and monetising technology smartly
and developing their own solutions practice for many years and the industry for productivity, development, and
in house, so there is most definitely has become too comfortable with it. sustainable growth.
some acceleration. And speaking from “However, we cannot see that still being In the meantime, back at Digital Flight,
experience, we know supply chain is a considered normal in five years’ time, they seem all geared up for the journey
focus point for many looking to automate so between then and now we must ahead to promote and generate industry
the lengthy process associated with demonstrate that there is a more efficient awareness about the wide range of
the procurement of a part. There has way, provide easy access and widespread technologies from one easily accessible
also been an emergence in blockchain awareness. Change is difficult, and it location.
There is a growing pursuit for digital solutions.
Photo: Lufthansa Technik
AviTrader MRO - August 202114
Composite Repairs
Composite repairs:
How are they
shaping up?
MROs are investing in repair capabilities for
heavily composite aircraft like the A350.
Photo: AFI KLM E&M
The demand for more fuel-efficiency, reduced operational costs and manufacturing have
propelled the use of new composite materials and subsequently, improved repair processes
as Keith Mwanalushi reports.
T
he aerospace industry has used With the pandemic still in circulation,
composites for some time now the GA Telesis leadership team quickly
on various applications especially took action to minimise the impact of
heavily composite aircraft like the B787. the pandemic to the businesses – “We
A recent market study suggests revenue reduced our costs by looking at every
from aerospace composites topped U$32 expense, even at the way we were buying
billion in 2020, prior to the pandemic coffee. We also worked with OEMs to
and expected to reach a valuation of place sizable orders of repair materials
over U$56 billion by 2031. to ensure supply chain integrity and
At GA Telesis MRO Services they avoid delay issues for our customers. By
have a fully capable composite repair taking these measures early, we were
facility and Ben Macre, Vice President, able to keep our customer's components
MRO Services – Composite says repair on time while keeping our team fully
solutions range from small-scale tailored employed through the pandemic and
engineering repairs performed on-wing maintaining our profitability in 2020,”
using heat blankets to large-scale repairs Macre reports.
using an autoclave. Beyond physically Meanwhile, at Vallair they provide
touching the aircraft or component, composite repair solutions referenced
GA Telesis supports operators with in the OEMs structure repair manuals,
assistance in repair design and the Ben Macre, Vice President,
and Steve Pike, Aerostructures and
fabrication of parts for ageing aircraft. MRO Services – Composite, GA Telesis MRO Services Sales Manager says
AviTrader MRO - August 2021Composite Repairs 15
Vallair provides composite repair solutions referenced
in the OEMs structure repair manuals.
Photo: Vallair
they also work closely with a DOA scrapped. “We successfully extend
when creating repair solutions outside the life of composite components
the scope of the SRM, thus in some providing cost effective solutions and
cases, they can conduct repairs where high-quality repairs,” he says. Vallair’s
the component would otherwise be capability listing covers a range of
composite components and panels Steve Pike, Aerostructures and MRO
including nacelles, thrust reversers, Services Sales Manager at Vallair.
engine inlet cowls, radomes and flight
control surfaces for Airbus, Boeing and more than ever before. “The market is
ATR aircraft. expected to grow through the increase
Pike explains that Vallair also carries in the use of composite technologies
a range of serviceable and overhauled and as operators and leasing companies
components on the shelf at its start to put their aircraft back in the
Chateauroux based composite repair skies. The pandemic has wreaked havoc
facility and therefore offers alternative amongst the industry and resulted in the
loan, leasing and exchange solutions demise of many operators, but we now
alongside the specialist repair and see evidence of new start-ups evolving
overhaul capabilities currently on offer. and filling the gaps left by those unable
Speaking on the pandemic Pike to survive.”
indicates that the outbreak has severely Scott Butler the Chief Commercial
impacted the entire aviation industry and Officer at Ascent Aviation Services also
those operators that are able to survive sees a general slowdown for composite
are without doubt seeking cost effective and component repair during the crisis.
repair and overhaul solutions extending However, he says this is picking up in
Scott Butler, Chief Commercial Officer,
Ascent Aviation Services the life of their composite components, 2021 with several clients in the leasing
AviTrader MRO - August 2021Composite Repairs 16
“
The increased use of
composite materials
in the newest
aircraft designs will
necessitate new
inspection techniques
and, ultimately, new
”
repair techniques.
Ben Macre, GA Telesis
sector trying to get all the needed
repairs done now while the aircraft are
on the ground.
Evolving technologies and
composite repair processes
Butler reckons the costs are a high
barrier to entry, but they have begun
by adding next-gen composite aircraft
to their OPSPEC at Ascent. “We plan on
serving both B787 and A350 at Ascent Revenue from aerospace composites
Marana and Ascent Roswell soon. We topped U$32 billion in 2020.
Photo: Vallair
definitely acknowledge that composite
is the future of aircraft, and we need to
position ourselves to serve this growing
market.” phase and one major issue is time equipment manufacturers to evaluate
Macre has seen changes to both the and labour costs given manual repairs new technology non-destructive testing
number of composites and the types are time consuming and expensive. equipment such as phased array,
of composites used on aircraft over the Investment in automated repair ultrasonic delamination tools, and 3D
years, he gives a good example being technologies will be required in the laser scanners,” he states.
the evolution from fiberglass toward future to reduce costs as well as the risk And over at Ascent Aviation Services,
carbon fibre – “The increased use of of human error.” Butler indicates that they are expanding
composite materials in the newest the component services offering as well
Investing in new generation
aircraft designs will necessitate new at all locations. “Our increasing share
aircraft services
inspection techniques and, ultimately, of leasing customers are continually
Macre reports that GA Telesis
new repair techniques,” says Macre. looking for one-stop-shops and we
continues to make significant
Obviously, repairing composite want to keep as much work on the field
investments in all its businesses,
as possible, to reduce lead times and
components requires specialist specifically with composites, to ensure
transportation costs.”
knowledge, skills, and capabilities they remain competitive. “We have most
Certainly, the aerospace industry has
and at Vallair they work closely with recently added a larger autoclave to
universally adopted composites and new
OEMs, operators and airworthiness accommodate the composite structures
repair techniques and the evolution in
authorities when creating repairs and installed on the latest generation of
the manufacturing technology of such
repair methodology in line with modern aircraft, including the B787 and A350.
composite parts will continue to drive
materials in use today. Pike states: We have just completed the build-
their use in aerospace applications.
“Repairability is something that the OEM out of our transmissivity test booth as
considers during their initial design well. We are also working with tooling
AviTrader MRO - August 2021Freighter
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FREIGHTER CONVERSIONS
A sweet
Spot for
conversion The new A321-200PCF is now in full operation with SmartLynx.
Photo: SmartLynx
The Covid crisis and the boom in e-commerce have triggered strong demand for all-cargo
aircraft capacity. Keith Mwanalushi speaks to the key players in the market about the
driving forces behind recent conversions.
S
ince the peak of the Covid crisis conversion slots run through Q1 2022, freighter conversion STCs as we develop
in May last year, more than 200 and they are in active discussions with additional product lines in our freighter
aircraft have joined the global prospective operators for each of those strategy,” Cho hints.
freighter fleet with newly converted positions. “We are also evaluating other At AEI they are currently offering
Boeing 737-800s and A321s making up five narrowbody conversion products to
a significant chunk of recent passenger- the global freighter market. These are:
to-freighter (P2F) conversions. Certainly, B737-800SF, B737-400SF, B737-300SF,
the demand to convert aircraft from MD80SF and the CRJ200 SF. “We currently
passenger to cargo use has grown have at least one of each type presently
significantly putting the air cargo sector in conversion with the majority of our
at the forefront of market recovery. backlog comprised of B737-800SF’s
GA Telesis has been ramping up and B737-400SF’s,” says Bob Convey,
its cargo related business over the AEI Senior Vice President of Sales and
last several months and now has a Marketing.
commitment for six 737-800SF freighters “We have seen a steady reduction in
under the Aeronautical Engineers Inc passenger aircraft pricing over the past
(AEI) conversion STC. “Our first aircraft 12 months which is having an effect on
was delivered to Ethiopian Airlines freighter values and lease rates,” Convey
earlier this year,” informs Marc Cho, observes. He adds that in recent months
Chief Investment Officer and President of the downward trend of aircraft pricing
L.I.F.T. (Leasing, Investments, Finance & has begun to level off and AEI are now
Trading) at GA Telesis. He says a second seeing a pricing plateau take affect which
aircraft has recently been delivered to will stabilise freighter pricing.
Compass Cargo Airlines, a wholly owned Conversion specialists IAI have been
subsidiary of ACT Airlines, both on long- busy too lately with their P2F conversions
Marc Cho, Chief Investment Officer and
term lease. Cho indicates that the other President of L.I.F.T. at GA Telesis for Boeing platforms – currently, it
AviTrader MRO - August 2021FREIGHTER CONVERSIONS 20
IAI is making new progress with its BIG TWIN B777-300 conversion programme.
Photo: IAI
provides P2F conversions for B737- P2F conversion site in Italy, which will
300/400/700/800, B767-200/300, and serve as the first such facility in Europe
B747-400 with over 250 aircraft having and by August IAI begun the structural
been converted. In July, IAI announced modification phase in the conversion of
a new partnership for a B737-700/-800 the first B777-300ERSF in partnership
GECAS.
“The Boeing platforms have proved to
be very successful for cargo conversions –
just as much as their aircraft performance
and maintenance programme from
the passenger configuration,” says Rafi Matalon, IAI Aviation Group VP Marketing
Rafi Matalon, IAI Aviation Group VP
Marketing. He also says IAI uses market of 53,000 lbs and a maximum volume
trends to create the right solutions for of 6,543 ft3. “These conversions are
operators and adjusts accordingly. fit for domestic operation for general
Clearly, transforming ageing cargo and e-commerce and furthermore,
passenger aircraft into cost-effective 21st all the aircraft receive FAA and EASA
century cargo platforms, and ensuring supplemental type certificates and other
dependable freighter performance is a civil aviation authorities' validations from
complex task. Matalon highlights two around the world.”
specific programmes as examples: The Observingly, Matalon comments on
B737-700 has a maximum structure the B737 Classics that are still operating
payload of 45,000 lbs and a maximum in Europe saying they will need to be
volume of 4,872 ft3, while the B737- replaced by newer converted B737-
Bob Convey, AEI Senior Vice President
of Sales & Marketing 800 has a maximum structure payload 700/800 aircraft, which is why IAI’s B737
AviTrader MRO - August 2021FREIGHTER CONVERSIONS 21
A321F to be operated by a European
based carrier. MSN 891 had been
prepared for delivery at Vallair’s specialist
MRO and painting facility in Montpellier,
France immediately following its
conversion in the USA.
And remaining in the USA, Precision
Aircraft Solutions have two narrowbody
conversion products- the A321-200PCF
and 757-200PCF. In addition to this, Zach
Young, Director of Sales and Marketing
tells that they also offer turn-key
engineering and manufacturing solutions.
Speaking to AviTrader MRO about
freighter values and lease rates in the
current environment Young says the
values pre-conversion versus post-
conversion are inversely related.
Scott Butler Chief Commercial Officer, Daniel Kirk, VP, Global Leasing and Cargo,
Ascent Aviation Services “Certainly, lower acquisition costs can Pratt & Whitney
mean lower on-ramp costs, but as long
platform conversions are fitted to the Aftermarket gears up for
as freighters are in short supply and high
market requirements – “IAI's new MRO support
in demand the higher market values of
conversion site in Italy will be a go-to Pratt & Whitney(P&W) recognises the
converted freighters will be supported.”
for new European customers, providing unique aftermarket offerings required
the comforts of proximity and excellent to meet the demands of the cargo
service,” he suggests. conversion market and has developed
Scott Butler, Chief Commercial Officer creative and agile solutions to effectively
at Ascent Aviation Services sees that support cargo customers, Daniel Kirk VP,
most of the activity currently is related
Global Leasing and Cargo explains. “We
to lease and operator transitions for
offer engine swaps for custom built
aircraft coming out of passenger
engines, purchases of engines already
operators and transitioning to
overhauled to fit cargo operators
the new lessor or cargo operator.
needs and overhauls for cost effective
Additionally, Ascent is partnering
cargo-specific maintenance.” He
with Sine Draco in conversion of
says P&W also provides entry into
A321 aircraft and we will begin the
service support, new and used material
conversion process in Q4 2021.
solutions, line maintenance services,
Due to the increase in available
engine health monitoring, and more.
aircraft for conversion Butler is observing
“Our solutions are tailored to make the
fluctuations in demand for services
ownership, operation and maintenance
to the freighter market – “Absolutely.
While previously an anomaly, there are
Zach Young, Director of Sales and of Pratt & Whitney engines cost effective,
Marketing, Precision Aircraft Solutions
many aircraft coming through our lease efficient, and preferred for the cargo
transition process and are leaving to go market,” Kirk highlights.
to freighter conversion.” And in terms of Young points out that the bottleneck Kirk calls attention to several factors
innovation in the sector he believes the in the freighter supply chain currently is contributing to activity around cargo
temporary zero-pax, cargo-only solutions the availability of conversion slots with conversions. Firstly, he says P&W
have been a very innovative way to utilise various providers. “As long as freighters powered 767’s and V2500 powered
a down-cycle in larger long-haul aircraft. remain in high demand, the freighter A320 and A321’s are starting to enter
Another platform gaining traction values and lease rates should not the sweet spot for conversion, with the
for conversion is the Airbus A321. In decrease. It is a possibility that we have right vintages becoming available. “That
June, cargo conversion specialist Vallair a future surplus of freighters, especially sweet spot balances the acquisition costs
delivered a second A321 freighter the 737NG, which could eventually cause and the remaining life in the aircraft and
conversion and this was the first ever values and lease rates to soften.” enables the value proposition to work
AviTrader MRO - August 2021FREIGHTER CONVERSIONS 22
out for conversion. The second element Manager says booming narrowbody
is the increased interest in cargo we freighter demand is a function of cost-
are seeing because of Covid, with belly effective feedstock becoming more
capacity down dedicated freighters have readily available. That is fuelling demand
been in high demand.” Kirk, like others and enquiries to The Aircraft Group for
in the industry sees that while some of technical support surrounding the entire
the pandemic induced freighter demand conversion process. “We are actively
is temporary, traffic across the board is engaged with multiple A321 conversions
recovering and belly capacity will come and enquiries to support additional
back and the trend towards e-commerce conversions is continuous. A key
is ensuring that freighter growth is a component of that aftermarket support
long-term trend. relates to engine support, the ability
In terms of engine values, P&W have to manage engine builds that meet the
seen values hold up well. Kirk says cost targets through reduced life cycle
while they had initially expected higher requirement of freighters i.e., shorter stub
pandemic-induced retirements, that has life or fewer remaining cycles required.”
not been realised and in fact, in 2020 The Aircraft Group has also seen
they saw V2500 retirements below trends. a resurgence of interest even in the
“Airlines have been holding on to aircraft remaining 757 airframes, and interest in
and engines to remain flexible for the other platforms including B777 for new
James Palacios, VP and General Manager at
recovery, and they are being proven door STC’s and conversion activity even The Aircraft Group
right as recovery is now projected to with smaller aircraft like ATR conversions.
happen faster than initially anticipated. And speaking of ATRs, Skyways
We see that bearing out particularly Technics offers to convert any passenger in the level of interest for software to
in the US, and increasingly elsewhere ATR aircraft into cargo configuration. manage freighter conversions, confirms
with encouraging indicators on vaccine This is done with the renowned AKKA Kirk Baugher, Executive Vice President,
rollout and resulting traffic recovery.” Kirk STC, which is the fastest way to convert Business Development at Pentagon
adds that the majority of V2500 engines passenger aircraft to cargo, according 2000 Software. However, Baugher points
were delivered later in the programme, to Mogens A Nielsen, the Production out that the available supply of lower
because of Airbus’ A320ceo production Director at Skyways. “From start to finish cost aircraft by itself does not justify
ramp up – “so we are looking at a young the aircraft can be converted in just the business case for conversions. “A
fleet that still has many years of life left.” five weeks,” Nielsen reports. So far, he recent increase in air freight due to the
The Aircraft Group provides a wide says the conversions are carried out on pandemic has created additional demand,
scope of services in support of cargo following types: ATR 42-300, 72-202 and but an offsetting increase in costs for
conversions, from start to finish. James 72-500. materials and
Palacios, Vice President and General There has been a recent increase
The 737-800 has proved a popular candidate as a freighter.
AviTrader MRO - August 2021
Photo: AEIFREIGHTER CONVERSIONS 23
and AEI’s position in that market, GA service.” Similarly, IAI see around 5000
Telesis is focused on the 737-800 and potential aircraft of this model and high
the AEI conversion STC to launch their market demand make the 737NG an
expansion into freighter aircraft leasing. ideal candidate for conversion – “The
Data given by GA Telesis shows that establishment of the centre [in Italy] is a
aside from improved fuel burn lower testament to IAI's growing impact around
operating cost and reduced maintenance the world,” Matalon notes.
cost because of longer maintenance At Precision Aircraft Solutions they
intervals, the 737-800 converted freighter have developed their expertise especially
also has increased cargo capacity both around the A321-200PCF and Zach Young
in the upper hold and the lower hold. points to several merits for conversion
As a result, Marc Cho says this aircraft of the type compared to similar aircraft
will provide a compelling option for on the market including additional full
both established cargo operators and main deck positions, significant volume
new entrants to the market looking to and payload advantages and additional
grow into the ‘express’ or e-commerce containerised volume. Young stresses
cargo space where next day delivery is that the A321-200PCF has the lowest
becoming an essential requirement. operating empty weight with the highest
Convey from AEI reckons the 737- standard payload among competing A321
800 is the ideal freighter conversion programmes.
Kirk Baugher, EVP Business Development at
Pentagon 2000 Software candidate for several reasons, built in With 59% of A321’s being powered
large quantities with just under 5,000 by the V2500, there is no doubt that
labour required to perform a conversion units in the zone of conversion meaning the V2500 is the preferred engine on
have dampened some of the enthusiasm,” the oldest units are just over 20 years the A321. From an A321 freighter
he stresses. old. He says these and other attributes perspective, naturally that means there is
The Pentagon 2000SQL system combined will make the 737-800 the a larger pool of V2500 powered engines
incorporates the full set of operations most popular freighter in history with that can be tapped into for conversion
software required to perform cargo an estimated 2,000 units potential being and it’s easier to build a uniform A321
conversions and includes integrated converted. freighter fleet around the V2500.
accounting and financials as an option to Following IAI’s collaboration with Kirk from P&W feels the V2500 fleet
tie it all together into a complete end-to- Atitech in Italy for a new conversion is very much in the prime of its life
end solution. facility Rafi Matalon explains that the and has a long future ahead, both in
new partnership will allow B737NG passenger and freighter service, as well
Narrowbody cash converters
aircraft conversions on multiple lines as in military service on Embraer’s C-390
Industry players have been ramping
and will expand the capacity to carry out Millennium – “That perhaps is one of the
up P2F capabilities with noticeable
such conversions, including potential best testimonies to the V2500’s staying
opportunities as a wave of narrowbodies
expansions in other types of conversions power, we will remain in production for
enter the freighter market, especially for
down the road. “Currently, the B737NG many years to come, not only ensuring
the B757, B737 and A321 platforms.
is beginning to phase out from the the story of the V2500 continues
Given the established base of
passenger world – at the same time, but also our commitment and
operators for the 737 Classic freighter
the 737MAX is gaining an entrance into support to our customers,”
Kirk ends.
IAI announced a new partnership for a B737NG P2F conversion site in Italy.
Photo: IAI
AviTrader MRO - August 2021FREIGHTER CONVERSIONS NEWS BLAST
Volga-Dnepr Group is Compass Cargo Airlines takes delivery of second B737-800SF freighter
ready to review MC-21 conversion
freighter version GA Telesis, LLC (“GAT”) announced
During MAKS 2021, International the delivery of its second B737-800SF
Aviation and Space Salon held in (MSN 28826) passenger-to-freighter
Zhukovsky (Russia), Volga-Dnepr (“P2F”) conversion to Compass
Group delegation headed by Cargo Airlines, Bulgaria. The aircraft
Chairman of the Board, Alexey was delivered from Aeronautical
Isaykin, visited MC-21-300 – the new Engineers, Inc. (“AEI”) authorized
generation Russian passenger plane Conversion Center, Commercial Jet,
which is going to be manufactured in Miami. This follows the delivery
in several modifications from 150 of the first B737-800SF freighter to Compass has recieved the second B737-800SF Photo: Compass Cargo
up to 211 seats. Ethiopian Airlines in March 2021.
During the visit, the companies GA Telesis’ Leasing, Investment, Financing & Trading (“LIFT”) Group has achieved great
discussed the possibility of the success since announcing their expansion in the air cargo market, leading LIFT to commit to four
production of a freighter version. additional firm orders for P2F conversions with AEI.
Amid the capacity constraints, "We are delighted to partner with Compass Cargo Airlines to provide their first B737-800SF.
emerging demand for freighters Compass Cargo Airlines is a new, rapidly growing operator in the narrow body freighter space,
and increase of cargo volumes and we are very pleased to be able to support their B737-800SF needs to facilitate their successful
worldwide Irkut Corporation believes expansion,” commented Marc Cho, President of LIFT.
it is in a favourable position to “We are ecstatic with the delivery of our first B737-800SF. The B737-800SF will allow us to offer
commence the freighter programe. our customers the most advanced narrow-body freighter technology with high fuel efficiency and
Volga-Dnepr Group might become increased capacities. GA Telesis is the ideal partner, supporting us to grow our fleet in accordance
the possible launch customer of the with the increasing demand for this aircraft,” said Pentcho Pentchev, Managing Director, Compass
MC-21-200 freighter version. Cargo Airlines, Bulgaria.
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AviTrader MRO - August 2021FREIGHTER CONVERSIONS NEWS BLAST
C&L Aviation completes first Saab 340B+ cargo conversion
C&L Aviation Services has completed a cargo conversion on a
Saab 340B+ at the company’s Maine-based MRO facility. This
is the first B+ model in the world that has been converted for
cargo operations. The operator, which has taken possession of
this aircraft, has signed an agreement with C&L to complete an
additional 5 conversions in 2021 and 2022.
For the conversion, C&L utilized an EASA- and FAA-approved
conversion kit provided by Sweden-based Täby Air Maintenance
(TAM’s), C&L’s partner in conversions since the two companies
signed an agreement in 2018.
“We have been pleased with the way this first B+ model C&L plans to convert 5 other B+ models in 2021 and 2022 Photo: C&L Aviation Group
project has come together”, said C&L CEO Chris Kilgour. The
Saab 340B+ models are aircraft with production serial numbers from 340-360 to 340-459. With low acquisition costs, and a maximum cargo
volume of 1,280 cu ft, and a maximum payload of 9,325 lbs., the Saab 340B+ is an ideal aircraft for cargo operation.
ATSG accelerates A321 strategy for conversion and lease
Air Transport Services Group, Inc. (ATSG), announced that its Cargo Aircraft
Management (CAM) leasing business has committed to purchase its first two
Airbus A321-200 passenger aircraft, one this year and a second in the first
quarter of 2022.
Freighter conversion of the first aircraft will begin in the fourth quarter of 2021
with its redelivery to a CAM dry lease customer projected to occur in the second
quarter of 2022. The second aircraft will begin freighter conversion in the second
ATSG sees huge potential in the A321 P2F Photo: Keith Mwanalushi
quarter of 2022 with redelivery projected during the fourth quarter of 2022.
Both aircraft will undergo passenger-to-freighter conversion at ATSG’s PEMCO Conversions facilities in Tampa, Fla. Recently, PEMCO
Conversions inducted its first A321-200 for conversion. The engineering design for passenger-to-freighter conversion was approved by the FAA
in April and is owned by 321 Precision Conversions, a joint venture of ATSG and Precision Aircraft Solutions.
AviAM Leasing adds BBAM orders new A321P2F freighter conversions from EFW
737-800BCF to fleet BBAM Limited Partnership (BBAM) and Elbe
In July, AviAM Leasing welcomed its first Flugzeugwerke (EFW), a joint venture of ST
737-800BCF to the fleet. The P2F conversion Engineering and Airbus, announced an agreement
project was the first of its kind for the for Airbus A320/A321 Passenger-to-Freighter
company. Having acquired the aircraft in (P2F) orders including options. The new orders
March 2021, AviaAM Leasing used the by BBAM bring the total number of its A320/
opportunity to begin strengthening its A321P2F to no less than 20, with the conversions
position in the freighter aircraft market. to be carried out by EFW through 2025. The
With a commitment to having ten 737-800 BBAM is now the largest aircraft lessor for the A320-A321P2F agreement comes with the option to add new
programme Photo: EFW
converted freighters by mid-2022, the conversion slots every year starting in 2026.
completed conversion on the company’s “With this latest order, BBAM is now the largest aircraft lessor for the A320/A321P2F
first Boeing 737-800 aircraft is a major step programme, and one of the top P2F customers of EFW,” said Andreas Sperl, Chief Executive
forward for the aircraft lessor. Officer of EFW. “The order volume by BBAM translates into a full conversion line with a
The 737-800 Boeing Converted minimum of five slots per year, with many of the conversions to be carried out at the airframe
Freighter (BCF) underwent the P2F facility of our parent company, ST Engineering, in the U.S. When combined with top-notch
conversion works at the Taikoo (Shandong) conversion standards, our A321P2F solution offers unique benefits for air freight activities,
Aircraft Engineering Company Limited including best-in-class economics, reduced noise, lower carbon footprint, real-time health
(STAECO) facility in Jinan (TNA), China. monitoring and the highest level in reliability.”
AviaAM Leasing also reports that “Our commitment to the P2F programme demonstrates our confidence in the ability of EFW
the second 737-800BCF has already and ST Engineering to deliver long-term value enhancement for the A320s and A321s in our
begun undergoing P2F conversion fleet,” said Steve Zissis, President and Chief Executive Officer of BBAM. “We have committed
work at GAMECO, Guangzhou Aircraft to the A320/A321P2F programme well into the future – beyond 2026 – because we see it as a
Maintenance Engineering, and after greener and highly innovative solution for our airline customers, and an excellent way to drive
successful completion of the conversion value for our investors."
process will be delivered to its ultimate In January this year, BBAM announced the delivery of the world’s first Airbus A321P2F on lease
tenant in the later stages of 2021. to Titan Airways.
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