AHEAD OF THE COMPETITION
Kansas Mod Center’s decision to place the main cargo door forward of the wing produces superior economics and operating utility. The design results in the lowest operating empty weight (0EW), maximizes payload and minimizes fuel consumption.
Putting a large cargo door aft of the wing is expensive and requires rear-fuselage modifications that add substantial weight, increasing the aircraft’s operating empty weight and fuel burn along with it.
LESS FUEL, SMOOTHER OPERATIONS
With its forward door design, KMC’s B777-300ERCF freighter – based on 4,000 annual flight hours – is projected to consume 205 lbs./hr. less fuel than a conversion using an aft door. That means millions in savings over the life of the P2F conversion. Having the main cargo door forward of the wing brings cargo-loading, operational and safety advantages.
More Front Door
Download PDF of the front door advantages.
Putting the main cargo door forward of the wing in KMC’s B777-300ERCF results in a projected operating empty weight (OEW) of 329,000 lbs. The low OEW allows the aircraft to carry a projected 205,000 lbs. in cargo payload while decreasing fuel consumption and extending range.
WEIGHT, FUEL ADVANTAGES
- Saves up to 7,000 lbs. over aft-door designs, translating into 200 lbs. /hr. fuel savings
- Saves $660,000 a year and $10 million over 15 years based on $6 a gallon fuel and 4,000 hours annual flight hours
- Increases payload revenue on longer routes
SAVING WEIGHT, MODIFYING LESS
A Boeing 777-300ER uses horizontal stabilizers to maintain level flight, which puts stress on the rear fuselage. Adding a cargo door behind the wing compounds the problem, forcing weight-adding reinforcements to handle the stress on the rear fuselage. A forward cargo door like KMC’s doesn’t add as much weight or stress.
AVOIDING MAJOR STRUCTURAL REINFORCEMENTS
- Lowers the empty operating weight and fuel consumption
- Results in fewer detailed structural inspections than a structurally reinforced rear door will require
- Smooths path to certification, there are fewer implications with aircraft’s original operating type certificate
CURTAILING TIPPING RISKS
The tail of any cargo aircraft can tip if proper procedures aren’t followed during loading procedures; however, KMC’s designs reduce the risk.
PREVENTING TIPS WITH FORWARD DOOR
- Shifting aircraft’s center of gravity minimizes risk of tail tipping
- Placing just two pallets ahead of the forward door pushes center of gravity forward, further reduces the tipping risk
- Utilizing a tipping alert system, with alarm and flashing lights, further reduces risk
- Combining optional powered cargo-handling system with alert system allows for auto shutdowns when alerts are triggered
EASING CARGO OPERATIONS
The B777-300ERCF’s forward-door placement provides numerous cargo-handling and operational advantages over a rear-door design. Many are derived simply by escaping the confines of the area between the wing and the tail where rear loading occurs.
- Offers “straight-in and out” approach, as 15 feet between door and engine inlet improves access for ground-handling equipment, pallets, loaders
- Allows larger cargo door that can accommodate 20-foot pallets and GE90/GE9X engines, an opening larger than the Boeing 777F has
- Improves cargo door access for left- and right-handed K-loaders vs. extra maneuvering around wing for aft door
- Has more cargo ramp area for ground-handling equipment, containers
- Provides more overall loading space, making full use of available forward loading area
Moving cargo handling into the unconfined space of a forward loading area provides safety and maintenance advantages over an aft-door placement.
ROOM TO MANEUVER
- Provides an overall safer ramp by keeping loading operations away from ground vehicle lanes and aircraft taxiing at the freighter’s rear
- Minimizes APU decibel exposure, making communication easier along with preventing APU exhaust in loading area and inside aircraft
- Reduces risk of loading equipment colliding with engines
- Allows crew to quickly assess if it’s safe to open the cargo door without hitting stairs, K-loaders or loading bridges
- Reduces susceptibility of engine blast blowing containers and ground-handling equipment into the freighter or taxiing aircraft
- Enables easy inspection of hazmat cargo containers, typically loaded last, by the crew
- Allows crew to visually check for proper door closure and to inspect cargo doorsill for damage and ice accumulation
- Enables wing maintenance, such as events involving flap extensions, to occur during cargo loading, saving time and money
- Allows both left-hand and right-hand K-loaders, as opposed to aft cargo door operation allowing only left-hand loaders
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.