Image: Kuehne+Nagel
As Boeing projects 50,000 aircraft by 2044, the race to move engines efficiently is reaching critical altitude.
The global aerospace logistics sector is witnessing unprecedented growth, fuelled by rapid fleet expansion, technological advancements, and the increasing complexity of modern aircraft engines. Boeing’s Commercial Market Outlook 2025–2044 projects the active commercial fleet to reach nearly 50,000 aircraft by 2044, an increase of 1.8 times compared to just over 27,000 aircraft in 2024. The freighter fleet is also set to expand significantly, growing by about 67% from 2,375 aircraft in 2024 to 3,975 by 2044.
Similarly, Airbus’s Global Market Forecast 2025–2044 anticipates demand for 43,420 new passenger and freighter aircraft over the next two decades. In this context, the movement of aircraft engines has become one of the most critical and demanding segments within global air cargo operations.
Aircraft engines represent far more than oversized cargo; they are high-value, technically complex assets requiring precision handling, specialised infrastructure, and expert coordination across global supply chains.
A growing market with rising stakes
The numbers tell a compelling story. Daniel Nyman, Vice President Global Aerospace Product Manager at Kuehne+Nagel, a leading global logistics provider with expertise in aerospace logistics, notes, “Aerospace logistics is one of Kuehne+Nagel’s core verticals, supported by nearly 300 dedicated aerospace professionals worldwide. Kuehne+Nagel manages more than 4,000 aircraft engine movements every year. The types of engines we handle vary by geography and airline. For example, in Europe, we primarily manage CFM56 engines, widely used on Boeing 737 and Airbus A320 aircraft; as well as LEAP engines, which power the Airbus A320neo and Boeing 737 MAX. On a global scale, the most commonly handled engine types include the CFM56, LEAP-1A/B, and Rolls-Royce Trent 700, 1000, and XWB.”
“Fleet expansion creates a domino effect: more aircraft translate into more MRO (Maintenance, Repair, and Operations) activities, and inevitably, more Aircraft-on-Ground (AOG) emergencies,” explains Nyman. “This growth not only increases demand for engines and spare parts but also highlights the need for skilled professionals.”
“Fleet expansion creates a domino effect: more aircraft translate into more MRO (Maintenance, Repair, and Operations) activities, and inevitably, more Aircraft-on-Ground (AOG) emergencies.”
Daniel Nyman, Kuehne+Nagel
These AOG emergencies represent situations where every minute of downtime costs airlines significant revenue and operational efficiency, making speed and reliability paramount in engine logistics operations. In some cases, manufacturer-specific issues can also trigger major AOG events. For instance, according to KPMG’s Aviation Leaders Report 2025: The Supply Strain, issues with Pratt & Whitney’s GTF engines grounded nearly 650 aircraft in November 2024. Spirit Airlines reported an average of 20 AOG events related to GTF engines during Q2 2024, while Wizz Air experienced 44 such events. Notably, Pratt & Whitney’s PW1000G family, also marketed as the GTF, powers aircraft such as the Airbus A220, the Airbus A320neo family, and the Embraer E-Jet E2.
Boeing estimates that an AOG situation lasting 1–2 hours can cost an airline between $10,000 and $20,000, and in some cases, costs may reach as high as $150,000.
The AOG challenge: when every minute counts
AOG scenarios represent the highest-pressure situations in aerospace logistics. When an engine failure grounds an aircraft, airlines face mounting costs from passenger disruption, crew redeployment, and lost revenue. In these critical moments, logistics providers must respond with ultra-fast coordination and execution.
“Aircraft engines are often shipped under AOG (Aircraft On Ground) emergency conditions, where every minute counts to minimise operational downtime. In these high-pressure scenarios, Rhenus must respond with ultra-fast coordination and execution to meet critical timelines and avoid costly delays,” says Moerowan Al-Chaabi, Global Group Strategic Account Manager & Special Projects, Rhenus Group, another major global logistics service provider with expertise in aerospace logistics.
Al-Chaabi explains that engine movements require precise scheduling and real-time visibility, adding that “Any disruption - whether due to weather, customs or handling - can trigger cascading effects across airline operations, making reliability and speed essential.”
“Managing a seamless flow across continents adds another layer of complexity. It demands synchronised efforts between Rhenus offices and accredited partners worldwide while facing time zone differences and regional regulations that challenge planning and execution,” he adds.
Specialised infrastructure: building for precision
The physical infrastructure required for engine handling represents a significant investment for logistics providers. Nyman describes how Kuehne+Nagel approached this challenge in Dubai: “At Kuehne+Nagel, we work closely with our customers to adapt to their specific requirements. In Dubai, for example, where we handle Rolls-Royce engines, we customised a 3,000 sqm facility by installing an electric overhead travelling crane with a 25-tonne lifting capacity, supported by a 64-metre runway and travelling bridge to optimise fulfilment operations.”
“Given that aircraft engines are high-value, technically complex items, they are subject to strict import/export controls.”
Moerowan Al-Chaabi, Rhenus Group
Challenge Group has taken infrastructure innovation further by developing specialised equipment at its operational hubs. Or Zak, Group Chief Commercial Officer at Challenge Group, explains: “Challenge Group has invested heavily in infrastructure at its hubs to support aerospace logistics. In Liège, we developed an in-house prototype engine dolly that allows for safer, smoother ground handling of engines. Our facilities are equipped with dedicated cranes, lifting devices, and docking systems that accommodate oversized engine types. We also maintain partnerships with specialised trailer suppliers for secure road transport, ensuring seamless multimodal transfers. Across our entire network, we operate under the same strict handling protocols, with teams trained and certified in complex verticals like aerospace.”
“Engines are high-value, oversized assets that demand a very different approach compared to standard freight,” Zak emphasises. “Safety, stability, and compliance are paramount. Each engine must be carefully assessed for dimensions, centre of gravity, and securement points. We employ tailor-made loading plans, reinforced restraint systems, and dedicated teams trained specifically in engine handling. Unlike general cargo, there is no margin for error. Correct securing and balance directly impact flight safety and the integrity of the engine itself.”
“The handling process for aircraft engines depends heavily on their size and weight,” Nyman explains. “Engine weights can vary from around 100 kg for light aircraft to over 6,250 kg for large turbofan engines, and up to 10,000 kg for those used in wide-body aircraft.”
Technology-driven visibility and control
In an industry where margins for error are non-existent, technology has become a critical enabler for secure and efficient engine movement. Modern logistics providers deploy sophisticated systems to maintain visibility and control throughout the supply chain.
“Technology is a critical enabler in the secure and efficient movement of aerospace engines, particularly under time-sensitive conditions such as AOG. Rhenus leverages a suite of digital tools and IoT-based solutions to ensure full visibility, control, and responsiveness throughout the logistics lifecycle,” says Brian Jansen, Global Key Account Manager at Rhenus Group.
Jansen explains that Track & Trace systems form the backbone of shipment monitoring, “providing real-time data on location, estimated arrival times, and handling status. These systems are integrated across Rhenus' global network, allowing both internal teams and customers to access live updates and exception alerts via centralised platforms.” Advanced sensor technologies play an increasingly vital role. “To enhance situational awareness and cargo integrity, advanced sensor technologies - including GPS trackers, shock sensors, and temperature monitors - are deployed on critical shipments. These devices transmit telemetry data that helps detect deviations from predefined thresholds, such as unauthorised route changes, excessive vibration, or exposure to non-compliant environmental conditions.”
Image: Rhenus Group
Rhenus takes a proactive approach based on risk assessment. “We recommend and implement these technologies based on the risk profile and urgency of each shipment,” Jansen notes. “For example, in AOG scenarios, GPS-enabled trackers with geofencing capabilities are used to ensure engines remain within secure corridors and arrive within the required time window.”
Kuehne+Nagel employs similar monitoring strategies. Nyman explains: “We use physical monitoring devices placed next to the engine to provide real-time data on temperature, humidity, and movement. This is essential, as even minor vibrations can cause damage if an engine is not transported on an air-ride vehicle designed to absorb road shocks.”
The integration of data across platforms enables predictive capabilities. As Jansen observes, “By aggregating sensor data, customs documentation, and transport milestones into a unified dashboard, Rhenus can identify patterns, predict delays, and initiate corrective actions before issues escalate. This technology-driven model not only improves operational reliability but also strengthens customer confidence by offering transparency, traceability, and tailored risk mitigation strategies.”
Critical control points and documentation
The handling of aircraft engines operates under stringent protocols that leave no room for improvisation. Nyman outlines Kuehne+Nagel's approach: “As part of our internal engine handling guidelines, we apply several Critical Control Points (CCPs) to ensure safe, end-to-end management of aircraft engines. For instance, only engine-certified team members are authorised to handle engines.”
“Every step of the process must be strictly followed and documented, both in writing and visually. Photos of the cargo are taken throughout loading, unloading, transport, and handling to verify full compliance with original equipment manufacturer (OEM) requirements,” he adds.
He emphasises the uncompromising nature of these operations: “Every engine movement demands meticulous planning and flawless execution. Factors such as vibrations, temperature changes, humidity, or exposure to the elements can all impact an engine’s integrity. The right equipment, from air-ride vehicles to specialised cradles, is essential. When it comes to safety and quality in engine handling, we make no compromises.”
Image: Rhenus Group
Al-Chaabi describes Rhenus's parallel commitment to standards and compliance. According to him, handling such sensitive cargo requires certified and trusted partners. “Rhenus enforces rigorous standards to ensure partner compliance with aviation regulations (e.g., EN/AS 9120), safeguarding both safety and reliability.”
Financial and operational transparency across global networks is equally critical. Al-Chaabi notes that “coordinating financial and operational settlements across the global network calls for robust systems and full transparency. Rhenus maintains clear accountability and traceability throughout the supply chain to support operational excellence.”
Handling dangerous goods and compliance challenges
One of the most complex aspects of engine logistics involves managing units classified as Dangerous Goods due to residual fuel. Engines arriving without proper purging or documentation can create significant compliance challenges.
Zak addresses this issue directly: “Residual fuel poses a compliance challenge, but our teams are fully trained in International Air Transport Association (IATA) Dangerous Goods Regulations and local authority requirements. Each engine undergoes inspection and classification before transport. Where fuel traces remain, we apply DG handling procedures, including specialised packaging, labelling, documentation, and segregation.”
He emphasises Challenge Group's integrated approach: “Thanks to our door-to-door business model, we manage every step, ensuring that regulatory obligations are met and that safety is never compromised.”
Beyond engines: a broader aerospace ecosystem
While engines dominate the high-value aerospace logistics segment, the industry encompasses a broader range of sensitive components requiring specialised handling. Avionics, composite materials, and landing gear each present unique challenges that demand dedicated infrastructure and expertise.
According to data from Verified Market Research, the aerospace logistics services market was valued at US$132.65 billion in 2023 and is projected to grow to US$267.03 billion by 2031, registering a CAGR of 9.1% during 2024–2031.
Jansen describes Rhenus's capabilities in this space: “Our facilities include dedicated handling areas designed for high-value, oversized and delicate items, including Out-of-Gauge (OOG) cargo and composite materials. These zones are equipped to meet strict environmental and safety standards, with certified and security-screened personnel trained in handling sensitive and regulated aerospace goods.”
He continues: “For storage and transport, Rhenus offers custom crate solutions for both road and warehouse operations, designed to protect fragile and high-value components. Our infrastructure supports specialised warehousing zones for composite materials and avionics, maintaining optimal conditions for preservation and safety.”
The integration of warehousing and MRO operations provides additional value. Al-Chaabi explains: “Rhenus plays a strategic role in warehousing and distribution for airlines and MRO providers by offering tailored logistics solutions for managing spare parts inventories. With dedicated facilities in aviation hubs like Dubai and Spain, Rhenus provides centralised warehousing that supports efficient inventory control, rapid distribution, and final assembly operations. For example, we’ve been operating for more than 10 years as a Spanish logistics hub for the Final Assembly Line of a large aircraft manufacturer.”
Next-generation engines and future growth
The introduction of new-generation engines is transforming aerospace logistics, as larger, heavier, and more sophisticated units enter service. The upcoming Boeing 777X family, including the next-generation freighter B777-8F, will be powered by General Electric’s GE9X engine, the largest and most powerful commercial aircraft engine ever built, with a 134-inch fan diameter.
“The introduction of new-generation engines is reshaping the industry with larger, heavier, and more sophisticated units.”
Or Zak, Challenge Group
Similarly, Rolls-Royce’s UltraFan, currently a demonstrator aero engine, is a next-generation, ultra-high-bypass geared turbofan featuring a 140-inch fan diameter.
Alongside these, existing engines such as the GEnx, Trent XWB, and LEAP families continue to represent significant technological advances. However, these next-generation engines also bring new logistical challenges, requiring ongoing investment in infrastructure and innovative operational solutions.
Zak sees this evolution as an opportunity: “The introduction of new-generation engines is reshaping the industry with larger, heavier, and more sophisticated units. Challenge Group is well-positioned to meet this evolution. Our expertise, investments in specialised infrastructure, and commitment to innovation, such as our engine dolly development, enable us to handle next-generation engines with confidence. We anticipate continued growth in aerospace logistics, driven by fleet modernisation and expanding MRO demand worldwide.”
Challenge Group's fleet expansion reflects this strategic positioning. The first IAI 777-300ERSF is expected to join its fleet in the coming months. This aircraft represents a significant step forward for Challenge Group, as it offers greater payload capacity, extended range, and the ability to accommodate outsized cargo such as aircraft engines with greater efficiency. Together with its current freighter fleet, the 777-300ERSF will strengthen its capacity to serve aerospace customers worldwide, reinforcing its role as a specialist partner for the transport of engines and other complex verticals.
Notably, IAI has recently approved its 777-300ERSF freighter, nicknamed the ‘Big Twin’, capable of transporting the Rolls-Royce Trent 1000 engine, marking a significant milestone in air cargo capability.
In addition, Challenge Group operates six Boeing 747 freighters and four 767 freighters, according to data from Planespotters.net, capable of transporting a wide range of aircraft engines, from narrowbody engines to larger widebody units on the 747Fs.
Image: Challenge Group
Meeting the skills challenge
As the industry grows, one critical challenge emerges: the need for skilled professionals capable of managing these complex operations. Nyman addresses this directly: “To bridge the gap between the rising demand for expertise and the limited availability of trained specialists, some airlines and MRO providers are investing in their own in-house training academies.”
Zak echoes this sentiment from Challenge Group's perspective: “Over the years, we have built a reputation for being a trusted partner in this vertical, offering a true door-to-door solution that ensures reliability across every stage of the journey. Our ability to manage end-to-end transport, from manufacturer or MRO facility to final destination, reinforces our position as a specialised supplier for this highly demanding sector.”
As the global aerospace industry continues its dramatic expansion, engine logistics will remain the backbone of fleet reliability. Precision, speed, and innovation in moving these high-value assets will determine how smoothly the skies stay connected.