Loaded with innovation that delivers savings

At the heart of Kansas Mod Center’s B777-300ERCF is a design that challenges the assumptions by placing the main cargo door forward of the wing instead of aft. But innovation matters little if it doesn’t deliver advantages. And KMC’s freighter conversion readily does.

  • Lowest operating empty weight (OEW) in the industry
  • Lower fuel consumption, reduced carbon footprint
  • Higher payload
  • Extended range
  • Streamlined path to certification
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Our design has many advantages and features in addition to the forward cargo door. Taken together, the KMC design results in a more cost-effective freighter that has an optimized production system to build and deliver.

  • Supernumerary cabin for crew rest and passengers
  • Rigid cargo barrier
  • A robust floor to meet the rigors of cargo
  • Federated flight displays, with primary flight software left alone

weights, range and routes: How B777-300ERCF compares

Efficiency and cost-effectiveness come in multiples with the B777-300ERCF design. It’s simple. By adding weight you burn more fuel and lose range. By keeping the operating empty weight down, KMC’s P2F conversion covers longer distances and hauls freight at a lower cost than competitors.

Consumes Nearly
205 LBs./HR. Less Fuel

Saves up to $660,000 a year and millions over the life of the aircraft

  • Has a lower carbon footprint
  • Reaches cities competing freighters cannot

Conserving weight and fuel, extending range

Kansas Mod Center’s decision to place the main cargo door forward of the wing saves up to 7,000 pounds, reduces fuel burn and minimizes payload-affecting fuel-range tradeoffs.

Routes, payloads and fuel

The effects of the B777-300ERCF's lower operating empty weight show in the payload and fuel numbers. The map shows just some of the routes where we've calculated the cost-effective benefits of KMC's P2F conversion.

Lowering Fuel Burn

KMC b777-300ERCF vs. aft-door freighter

See all the numbers

Seasonal variations, of course, affect fuel, payloads and range. In addition to 20-year average numbers for popular cargo routes, we’ve run the numbers for different seasons.

full route stats

DELIVERING FREIGHT VOLUME FOR LESS

The tables and payload-range chart tell the story. The B777-300ERCF from Kansas Mod Center delivers freight by volume at the best unit cost on the market.

MZFW-MTOW INTERSECTION

KMC’s B777-300ERCF, loaded to the limitations of maximum zero fuel weight (MZFW) and departing with fuel to maximum takeoff weight (MTOW) limitations, delivers the most cost-effective combination of freight volume and range. It will cost 25% less per cubic foot than the Boeing 777F with nearly the same payload.

MTOW-MAXIMUM FUEL INTERSECTION

The B777-300ERCF, loaded with maximum fuel and payload to MTOW limitations, is the most cost-effective option for delivering freight volume – at a trip cost 31% less than the closest competitor, the Boeing 777F.

Freighter payload range comparison overview
MZFW-MTOW INTERSECTION
Aircraft
PAYLOAD
LBS.
VOLUME
CU. FT.
FUEL FLOW
LB./HR.
COST/UNIT VOLUME
$USD/CU.FT./1,000 NM
COST/PAYLOAD
$USD/LB./1,000 NM
KMC B777-300ERCF
205,000
31,448
20,891
$0.88
$0.135
B777F
228,700
25,192
20,487
$1.10
$0.122
B747-400F
249,100
28,478
28,270
$1.30
$0.149
MD-11F
200,309
21,656
21,860
$1.35
$0.146
MD-10-30F
177,500
14,200
20,966
$2.00
$0.160
MZFW-MTOW INTERSECTION
Aircraft
PAYLOAD
LBS.
VOLUME
CU. FT.
FUEL FLOW
LB./HR.
COST/UNIT VOLUME
$USD/CU.FT./1,000 NM
COST/PAYLOAD
$USD/LB./1,000 NM
KMC B777-300ERCF
124,137
19,197
19,197
$1.33
$0.203
B777F
127,637
14,060
18,566
$1.75
$0.193
B747-400F
158,733
18,147
24,497
$1.77
$0.202
MD-11F
115,000
12,433
18,200
$1.96
$0.212
MD-10-30F
98,890
7,911
20,360
$3.49
$0.279

FLEXIBLE CARGO LOADS

The B777-300ERCF can handle numerous ULD load configurations.

FLEXIBLE CARGO LOADSFLEXIBLE CARGO LOADS

ADVANTAGES ALL AROUND

Innovation starts with the forward cargo door but doesn’t end there. The aircraft’s floor is strengthened, a supernumerary cabin is installed for crew rest and passengers, and flight displays are updated for freight operations. Combined, they assure a streamlined path to certification for the B777-300ERCF, which will be produced in Wichita by engineers and technicians who know their way around Boeing aircraft.

A BETTER FLOOR

Hauling freight instead of passengers requires a floor that can withstand the weight and abusive treatment cargo brings. After close study, our engineering team concluded that replacing the B777-300ER’s existing composite beams with new aluminum beams was a better plan for cargo operations.

THE ALL-NEW ALUMINUM BEAMS AND DECK

  • Create a floor exclusively designed for cargo
  • Add durability to withstand the rigor of freight handling
  • Improve integration with the Telair cargo-loading systems
  • Allow 33 cargo positions handling at least 9.6 lbs. per cubic foot each
  • Has ability to carry large jet engines including the GE90 propulsor and fan
  • Include drainage systems to carry live animals – supported by ECS (environmental control systems)
Main deck floor structure
Main deck floor structure

CABIN AND CARGO BARRIER

As part of KMC’s P2F conversion, we add a supernumerary cabin and a 9G rigid cargo barrier. Passenger doors and windows are plugged. Importantly, the conversion has federated flight displays and does not modify the existing certified software, keeping the aircraft within the operating limitations of its original certification.

RIGID CARGO BARRIER

  • Aluminum machined structure
  • Sliding doors for cargo compartment access
  • Meets emergency landing requirements
rigid cargo barrier
rigid cargo barrier

SUPERNUMERARY CABIN

  • Crew rest compartment with 2 bunks
  • Two jump seats
  • Vacuum waste
  • Galley with refrigerator, oven and coffee maker
  • 4 business class reclining seats for passengers
supernumerary cabin

EXPLORE THE B777-300ERCF

Interested in KMC’s freighter conversion? Want to meet the team designing it and bringing it to certification? We can readily share details and even show you around our facilities.

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CERTIFICATION, LOCATION,
REALISTIC TIMELINES

Kansas Mod Center’s straightforward approach of keeping the freighter’s design in concert with the parameters of the original manufacturer’s type certificate enables a clean and expedited path to certification.

KEY FACTORS IN SMOOTHING WAY TO CERTIFICATION

  • Leaving primary flight software untouched
  • Avoiding extensive aft-fuselage modifications and additional weight a rear cargo door brings
  • Remains within the designed limitations of the Boeing type certificate

CRAFTED IN WICHITA – THE AIR CAPITAL

We’re engineering and producing the B777-300ERCF in Wichita, Kansas, where labor costs are reasonable, aviation expertise is high, and the supply chain is local and solid. Our team members average over two decades of experience and know how to design the aircraft, build it, and achieve certification.

At Kansas Mod Center, we’re aggressive yet realistic in our timelines. We have a proven track record of delivering on time and on budget.