Navigating the challenges of cargo conversion projects

As a respected international provider of CAMO and technical services to airlines and lessors, Air Worthy has developed its position as a specialist in the complex process of passenger to freight (P2F) conversion programmes.

What is CAMO?

Continuing Airworthiness Management Organization or ‘CAMO’ is the process of ensuring that all aircraft are maintained to the highest level of safety. It is essentially an approval given by a National Aviation Authority (NAA) to an aircraft maintenance company, within its region of jurisdiction, that demonstrates the firm complies with the necessary aviation safety regulations. The CAMO designation, also referred to as Part-M, is mandatory for all EU-registered aircraft. It is a part of EASA’s Implementing Rules EU 1321/2014 - Continuing Airworthiness.

Employed by the aircraft owner /lessor directly or by the airline/operator, a CAMO manages responsibility for all continuing airworthiness activities, such as forecasting and compliance of the maintenance programme, Airworthiness Directive compliance, Service Bulletin evaluation and implementation, test flights, defect rectification and the safekeeping of accurate aircraft records.

The role of a CAMO is therefore highly complex. It requires many disciplines, all focused on aircraft safety, including: liaison with relevant authorities on behalf of an aircraft owner/lessor; finding solutions to technical issues; updating of aircraft technical manuals; performing  physical inspections and safeguarding records. When outsourced, a CAMO representative may be permanently based on-site during a heavy maintenance check or complex STC (Supplemental Type Certificate) modification, to oversee the process and ensure the schedule is kept on track.

Many aircraft operators now sub-contract CAMO to external specialist consultancies, such as Air Worthy, as it provides instant access to experienced technical expertise and knowledge.

In the case of passenger to freight (P2F) conversions, which have increased in the past few years, the aircraft requires major structural modifications to its approved Type Certificate (TC) from its original manufacture. Since the TC certifies the airworthiness of the aircraft’s designated design and intended operational performance, a Supplemental Type Certificate (STC) must be ratified before the converted aircraft returns to service, which rubber stamps the airworthiness of major modifications.

A P2F conversion project typically takes several months to complete, depending on the extent of the modifications. Whilst the cost is also dependent on the specific work involved, the whole process is significantly less expensive (and quicker) than purchasing a new cargo aircraft, making this an attractive and time-sensitive proposition for airlines, not least because of the ongoing difficulties with acquiring new aircraft.

Based in Italy, Air Worthy has significant experience in managing the complex challenges related to freighter modifications. The company has already helped to deliver a number of Boeing 767 and 747 conversions for international operators and is currently involved in the conversion of three 767-300 aircraft, as sub-contracted CAMO.

Air Worthy’s Accountable Manager, Gabriele Brescianino, said:

“Having been closely involved in a number of Boeing P2F conversions, our team brings a great deal of engineering knowledge and experience to customer projects in our role as CAMO.  Our trusted service is comprehensive, so we are able to deliver a solution that delivers not only the required technical expertise but also value for the client. The market for conversions is growing, so this is certainly an area which Air Worthy expects to develop further in 2025.”