Wide-body freighter conversions top narrow-bodies for first time since 2009
Dhaka: Wide-body passenger-to-freighter conversions surpassed narrow-body conversions in 2025 for the first time since 2009, marking a significant shift in the freighter conversion market driven largely by a narrow-body oversupply.
Aviation advisory firm IBA highlighted the development recently during its "The Freighter Outlook, Values & Conversion Trends" webinar. Senior aviation analyst John Whaley noted the change was caused primarily by a slowdown in narrow-body conversions rather than a surge in wide-body activity.
Narrow-body conversions fell to fewer than 20 in 2025, a steep drop from roughly 70 in 2024. The oversupply stems from a rush of orders placed in the immediate aftermath of COVID-19, when aircraft owners sought to utilize idle narrow-body jets amid a booming cargo market.
Wide-body conversions, meanwhile, totaled 30 in 2025, down from 40 in 2024, as the sector grapples with a shortage of feedstock. Whaley noted that wide-body aircraft had been retained in passenger operations in recent years due to their high value.
"Wide-body capacity is limited, and it seems to be getting worse, not better," he said.
IBA expects narrow-body oversupply to persist until at least 2028, with approximately 20 conversions projected for 2026. Wide-body conversions are expected to edge just above 30 this year, supported by more available programs and improved feedstock as older aircraft retire from passenger service.
777 programs expanding
The Boeing 777 conversion segment is seeing growing operator interest. In September 2025, IAI delivered its first two 777-300ERSFs to launch operator Kalitta Air through AerCap, followed by three more to Fly Meta in December. Challenge Group's first 777-300ERSF became operational in March.
Mammoth Freighters secured FAA Supplemental Type Certification in April for its 777-200LRMF conversion and is pursuing certification for its 777-300ERMF variant later this year. Kansas Modification Center (KMC) also announced cargo door milestones in January, targeting flight testing of its 777-300ERCF freighter in the third quarter.
Other conversion programs
The Boeing 767-300ER market remains active. Whaley confirmed Amazon and Cargojet have already taken deliveries this year. Cargo Aircraft Management was set to receive more before year-end, though he cautioned that feedstock for the type is becoming scarce.
The Airbus A330-200 and A330-300 are gaining traction. IAI completed primary structural work on an A330-300BDSF prototype and expects certification by year-end. The A330-200 saw 10 conversions in 2025, with growing demand in China from carriers including Air Cargo China, JD Air Cargo, and ZTO.
Boeing 737 conversions also remain active. In January, KF Aerospace gained certification for the world's first 737-800 combi conversion. Aeronautical Engineers Inc. is developing a 737-900ER conversion program targeting a 2029 launch, though Whaley noted there is no urgency given current market conditions.
IBA projects conversion activity across both segments to increase meaningfully between 2028 and 2030.