How is air cargo decarbonising to build a sustainable future?

With the global freighter fleet projected to grow by 70% in the next two decades—from 1,770 to 3,010 aircraft—and freight capacity anticipated to rise by 4.1% annually, the industry's environmental footprint is a pressing challenge. Recognising this, regulatory bodies such as the International Civil Aviation Organisation (ICAO), and industry associations like the International Air Transport Association (IATA) and The International Air Cargo Association (TIACA) are driving industry-wide efforts toward sustainability.

At the Future Aviation Forum 2024 in Riyadh, Salvatore Sciacchitano, President of ICAO, announced the creation of a roadmap to guide stakeholders toward sustainability goals, complementing IATA's goal of net-zero carbon emissions by 2050.

The air cargo sector is embracing innovations like fleet modernisation, sustainable aviation fuels (SAF), and energy-efficient operations. Airports are also incentivising SAF usage, and digital optimisation is helping reduce waste and emissions.

Is SAF a solution for sustainable aviation?
As the aviation industry strives to reduce its carbon footprint, Sustainable Aviation Fuel (SAF) has emerged as a key solution for decarbonisation. Derived from renewable sources like used cooking oil and agricultural residues, SAF can cut lifecycle carbon emissions by up to 80% compared to traditional jet fuel. For air cargo, which relies on long-haul flights, SAF offers a sustainable option while maintaining operational efficiency.

Supportive policies are critical to scaling SAF production.”

Alexander Kueper, Neste.

IATA projects that SAF will represent 65% of the emission reductions needed to meet the industry's 2050 climate targets. "When used in neat form, SAF reduces greenhouse gas emissions by up to 80% compared to fossil jet fuel," stated Alexander Kueper, Neste's Vice President for Renewable Aviation. Neste's MY SAF, made from 100% renewable waste, is produced using the Hydrotreated Esters and Fatty Acids (HEFA) technology, which Kueper notes is the most commercially viable method for producing SAF today.

Sustainable Aviation Fuel (SAF) currently accounts for less than 1% of global aviation fuel consumption, with key barriers being high production costs and limited feedstock availability. Greg Schwendinger, Vice President of American Airlines Cargo, highlighted that most SAF production utilises the Hydroprocessed Esters and Fatty Acids (HEFA) process. Since adopting HEFA SAF in 2020, American Airlines Cargo has utilised 3.6 million gallons, with plans to replace 10% of its jet fuel with SAF by 2030 as part of its goal for net-zero emissions by 2050.

The limited supply of traditional feedstocks, such as waste fats and oils, has led companies to explore alternative methods. Advanced technologies, like Honeywell's Fischer-Tropsch Unicracking process, aim to broaden feedstock sources to include municipal waste, crop residues, and CO2. Honeywell asserts that its method can produce 3-5% more SAF while also reducing costs by up to 20% compared to conventional techniques, enhancing the economic feasibility of SAF.

“The future of aviation is sustainable.”

Ranjit Kulkarni, Honeywell India

In an interview with The STAT Trade Times, Ranjit Kulkarni, Vice President & General Manager of Energy and Sustainability Solutions at Honeywell India, highlighted the importance of technological innovation in SAF production. "Our hydrocracking technology addresses the challenge of limited traditional SAF feedstocks by enabling the use of a wider array of materials like municipal waste, crop residues, and biomass. This broadens the feedstock pool and enhances supply chain sustainability."

To meet the increasing demand for sustainable aviation fuel (SAF), American Airlines has partnered with Infinium, a low-carbon jet fuel producer, and is investing in technologies to reduce lifecycle emissions by up to 100%. Schwendinger noted, "This partnership aims to support the long-term production of SAF."

"Supportive policies are critical to scaling SAF production," noted Neste's Kueper, adding that voluntary demand by businesses to reduce the carbon footprint of their travel and air freight operations can provide additional momentum.

To tackle the limitations of traditional feedstocks, innovative technologies are essential. Honeywell's hydrocracking technology converts Fischer-Tropsch liquids and waxes from biomass and municipal waste into sustainable aviation fuel (SAF), expanding feedstock options and promoting a sustainable supply chain.

DG Fuels is partnering with Honeywell to build a biofuel facility in Louisiana, set to produce 13,000 barrels of SAF daily by 2028. This facility will power over 30,000 transatlantic flights annually, significantly reducing the industry's carbon footprint.

Kulkarni optimistically stated, "The future of aviation is sustainable. With continued advancements in SAF production and supportive policies, we can achieve the aviation industry's ambitious climate goals. It's not just about flying cleaner but also about paving the way for a greener global economy."

On the other hand, James Golding, Head of Cargo at London Heathrow Airport, emphasised Heathrow's SAF initiatives, saying, "By subsidising the gap between traditional aircraft fuel and SAF, we can drive up the use of these fuels at the airport." Heathrow's SAF scheme targets 11% usage by 2030 and aims to reduce carbon emissions by 341,755 tonnes annually.

However, at the World Aviation Festival in Amsterdam, Breeze Airways CEO David Neeleman expressed scepticism about SAF, describing it as inefficient and economically unviable. He argued that an emphasis on SAF could lead to higher ticket prices, disrupt food supplies, and fail to tackle broader climate challenges effectively. Instead, Neeleman advocated for investments aimed at making diesel-dependent industries more sustainable.

His views conflicted with IATA CEO Willie Walsh, a strong supporter of SAF, leading to a heated debate between the two. While SAF is considered a component of aviation's path to achieving net-zero emissions, its high costs and partial viability continue to generate differing opinions within the industry.

While the debate around SAF's practical use and economic viability continues until we reach a conclusion, the air cargo sector also explores options like adopting renewable energy and reducing waste to decarbonise the industry.

Waste management: A crucial element of sustainability in aviation
IATA estimates over 3.6 million metric tonnes of cabin and catering waste are generated annually, and this figure is expected to increase as passenger and cargo volumes rise. So, addressing waste management is essential for the sector's sustainability.

Airports worldwide are pioneering sustainable waste management practices. For instance, Edmonton International Airport (YEG) leads in waste reduction through innovative methods like recycling maintenance waste, reusing construction materials such as asphalt millings, and employing CarbonCure technology in concrete projects to embed carbon dioxide, reducing emissions while strengthening materials.

Hong Kong Air Cargo Terminals Limited (Hactl) has introduced creative solutions like turning recycled plastic bottles into staff uniforms and repurposing old uniforms into upcycled cups. Such initiatives demonstrate the potential of circular economy principles in waste management.

On the other hand, Lufthansa Cargo collaborated with IRED to upcycle old freight containers into products like travel trolleys and clocks, blending sustainability with innovation. This approach not only reduces waste but also educates stakeholders on creative reuse.

British Airways has set ambitious targets, aiming to recycle 40% of onboard waste and reduce waste per passenger by 20% by 2025. In 2023, the airline launched sustainable crew uniforms, crafted from 90% recycled materials, and repurposed old fabrics into school uniforms for children in Bangladesh. Its initiatives to replace single-use plastics with alternatives like bamboo and paper further demonstrate its commitment.

Emirates has taken significant steps to reduce waste in its operations. The airline introduced a limited-edition collection of bags and accessories made from upcycled materials from retired aircraft. Proceeds from this collection, showcased at the Dubai Airshow, will benefit children in need through the Emirates Airline Foundation, highlighting its dedication to both sustainability and social responsibility.

Despite these efforts, the aviation industry faces challenges like inconsistent regulations across regions. IATA's Single-Use Plastic Products (SUP) Report emphasises that waste management processes for EU-generated waste differ significantly from those applied to non-EU waste, leading to inefficiencies.

From developing reusable materials to replacing single-use plastics, airlines are exploring diverse methods to minimise waste. For example, LATAM Airlines aims to become zero-waste-to-landfill by 2027 and has implemented reusable pallet covers in cargo operations, eliminating 1.7 tonnes of single-use plastics in 2023 alone.

Airports are making significant progress in sustainability through initiatives like the Airport Council International's Green Airports Recognition program, which promotes best practices in waste management and acknowledges outstanding projects.

As Paul Terstegge, Executive Vice President of Inflight Services at KLM, stated during an IATA event, addressing the challenges of waste in aviation requires collective action. It is essential to harmonise regulations and adopt innovative technologies to create a unified approach that transforms waste management in aviation into a fundamental aspect of sustainability.

However, Terstegge also pointed out that sustainable solutions are not always feasible or economically viable. For instance, if we consider completely eliminating single-use plastics, we may need to explore alternatives like glass or aluminum, which would increase the overall weight. "In aviation, we know adding more weight means more CO2 burn," added Tersteggeon.

Through bold initiatives and collaboration, the aviation sector is taking meaningful steps to reduce its environmental impact, ensuring that growth is balanced with responsible waste management.

The role of renewable energy in sustainability
Aviation, a cornerstone of modern connectivity, contributes approximately 3% of global CO₂ emissions. As one of the most challenging industries to decarbonise, its growing environmental impact calls for innovative solutions. With passenger and cargo volumes rising annually, addressing emissions through renewable energy adoption has become critical for a sustainable future.

Hydrogen as a rising fuel source for ground operations

Hydrogen fuel is emerging as a promising renewable energy source in aviation. Collaborating with Toyota Canada and Air Products, YEG has adopted hydrogen-powered vehicles and installed an interim mobile hydrogen refueler to support a fleet of Toyota Mirai cars. The airport is also exploring hydrogen for SAF and industrial vehicle conversions.

Global airports are similarly integrating hydrogen-powered ground support equipment (GSE). Singapore's Changi Airport is deploying hydrogen-powered ground power units, while Kansai Airports in Japan has utilised hydrogen refuelling facilities and vehicles since 2014. In the UK, Exeter Airport is testing hydrogen-fueled GSE to cut diesel use during aircraft turnarounds, and Brussels Airport is piloting hydrogen-powered towing tractors.

These efforts highlight hydrogen's potential in reducing operational emissions, but achieving sustainability will require hydrogen derived from renewable sources. Feasibility studies and collaborations with green energy providers are essential to build the infrastructure needed for hydrogen-based aviation.

Airports driving renewable energy adoption
Airports worldwide are leveraging renewable energy to minimise emissions, targeting Scope 1, 2, and 3 emissions—from direct operations, purchased energy, and external stakeholders. Several pioneering airports illustrate the transformative power of renewables:

• Dubai International Airport installed the region's largest solar energy system at Terminal 2, comprising 15,000 photovoltaic panels that generate 29% of the terminal's electricity needs.
• Rome-Fiumicino Airport has a 60 MW photovoltaic system and plans to install 500 EV charging stations, significantly cutting its carbon footprint.
• Sofia Airport in Bulgaria is transitioning its ground-handling fleet to electric vehicles, with 34 electric and hybrid vehicles and 22 charging stations.

Canada's Edmonton International Airport is advancing renewable energy with the Airport City Solar project, which will be the world's largest solar farm at an airport. Spanning 627 acres and developed with a $169 million investment, the farm will generate 120 MW of power—enough to supply 27,000 homes. Expected to offset 106,000 tonnes of CO₂ annually, this ambitious initiative supports YEG's goal of carbon neutrality while contributing power to the Edmonton Metro Region.

Indian airports are also setting benchmarks in renewable energy:

• Cochin International Airport became the world's first fully powered by solar energy in 2015. Its 12 MWp solar plant generates 50,000–60,000 units of electricity daily, making the airport entirely energy-neutral.
• Delhi's Indira Gandhi International Airport runs exclusively on hydro and solar power, eliminating 200,000 tonnes of CO₂ emissions annually.
• Mumbai's Chhatrapati Shivaji Maharaj International Airport introduced a hybrid system combining wind turbines and solar panels, producing 36 kWh of clean energy daily while being bird-friendly and maintenance-free.

These advancements position Indian airports as global leaders in sustainable aviation, aligning with the country's net-zero carbon emissions target by 2030.

Airports tapping into geothermal energy
Geothermal energy, a steady and renewable heat source beneath the Earth's surface, is gaining traction at airports. Dublin Airport is exploring geothermal systems to meet its heating and cooling demands, with a detailed study due by 2025. Other airports, including Copenhagen, Paris-Orly, Amsterdam Schiphol, and Vancouver International, already use geothermal systems to reduce emissions and operational costs.

In the U.S., Louisville Muhammad Ali International Airport (SDF) is implementing a geothermal system with 648 wells, expected to reduce emissions by 80% and save $400,000 annually. SDF's Next Program exemplifies how geothermal energy can drive efficiency and sustainability in airport operations.

The road ahead

Renewable energy adoption in aviation is not just a necessity but a moral imperative to safeguard future generations. Initiatives such as hydrogen-powered GSE, large-scale solar projects, and geothermal energy systems illustrate the industry's commitment to sustainability. However, these efforts must be complemented by robust policies, financial incentives, and international collaboration to drive widespread change.