Alenia Corners MDC Conversion Market

The requirement for freight aircraft by the year 2005 is expected to increase by some 235%. It is toward this growing importance ofair freight that Alenia, the Italian state aerospace company, is investing its not inconsiderable resources for the modification and conversion of airliners to cargo roles.

One distinct advantage the company holds over its competitors in the conversion and modification industry are the exclusive licences ithas received from McDonnell Douglas, providing manufacturer endorsements on all conversions. Working co-operatively with MDC allows Alenia to maintain complete design integrity of fuselage and components which is an accreditation that no other company may offer.

In 1985 Alenia received its first MDC certification for the conversion of DC-8 passenger aircraft to freight configuration. In the same year it performed the firstsuch workfor Air Canada, and has since received substantial contracts from leasing and express freight companies for the conversion of 46 DC-8s. The group’s facilities in Venice, Naples and San Antonio in Texas (Dee Howard Co) all have the capability for DC-8 conversion, whilst the Venive facility alone manufactures DC-8 cargo doors for its own conversions, and under subcontract to MDC. To provide total support for its conversion program of the type, Alenia bought the entire DC-8 workshop from MDC and it has also developed cargo modification kits for sale to customers with their own overhaul and maintenance facilities.

Substantial contracts have recently been awarded by Guinness Peat for 26 DC-8s to be re-engined, overhauled and reconfigured for freight operations. Meanwhile, United Parcel’s five year $US400 million contract for their DC-Bs has provided the programme with sufficient work for it to continue until the end of 1993.

Despite the success of the DC-8 conversion programme for Alenia the DC-10 modification programme is considered to hold the brightest future for Alenia. There are currently 115 series-10 and nearly 300 series -30 DC-10 variants flying, and with an average age of 13 years, many of these aircraft are slated for the second hand market in the near future as new models are delivered to airlines.

In 1991 Alenia received an exclusive licence from McDonnell Douglas for the conversion of the trijet. To date twoDC-lOs have been converted for Federal Express. The average of conversion for a series -10 aircraftis between $US6-$8m, and $US5-$6m for series 30 types, dependent upon the operational history of the aircraft and specific customer requirements.

With a substantial number of DC-l0s to become available on the second hand market within the next decade, Alenia will be happy to gain contracts for the conversion of at least 10% of the remaining useful aircraft.

One senior MDC official states that Alenia is placed in a strong position for its conversion of DC-10 aircraft, given the close working relationship that exists between the two companies, and the active push by MDC to remove older aircraft such as the DC-10 from current passenger fleets in favour of the sale of new models to airlines.

In consolidating the relationship with McDonnell Douglas, Alenia was awarded an exclusive licence in 1992 for the conversion of MD-1ls. Alenia has already completed the first such modification for Federal Express, with N614FE becoming the first of the new transports to be modified from passenger configuration to pure freight use. The aircraft was delivered to the Aeronavali facility in Venice in July 1992 immediately after production flight checks and with only 25 flight hours accumulated. This MD-11 post production cargo conversion was the result of a slot change in the production line.

The $US4m conversion was completed in 13 weeks, and involved the cutting and area reinforcement of the forward left the installation 3. 5×3. 4m main cargo door. Floor modification, reinforcement and seat track repositioning was made to allow for the installation of a standard cargo loading system, which was placed on new aluminium and balsacore floor planing. The electrical, hydraulic and environmental systems were also modified and reworked to satisfy the cargo interior systems requirements. Federal Express’s specific requests regarding the interior lining, lavatory and galley repositioning, and the installation of a courier station were also met.

Weights and payloads of the MD-11 have been altered to suit the aircraft’s new role. The maximum gross takeoff weight has been increased by 7037kg (15,5001b) to 280,572kg (618,000lb), with an operating empty weight of 113,752kg (250,5551b), a decrease of 17,363kg (38,2451b) as a result of the removal of interior fixtures and fittings.

The gross weight limited payload of 91,138kg (200,7451b) is substantially increased on the passenger version’s 51,105kg (112,5641b). The maindeck cargo area is capable of transporting 26 pallets (244x318cm/96″xl25″), while the lower deck holds 32 LD-3 containers plus l4m3(510cu/ft) of bulk freight, providing a combined cargo volume of 602m3 (21,288cu/ft). Range of the MD-11 at 82,150kg (180,9481b) is 4000nm (7410km).

Although it is not anticipated that there will be any more conversions in the immediate future, given the MD-ll’s recent entry to service, the Federal Express MD-11 conversion has placed the company in a strong position for the future second hand market of the model.

Alenia has enjoyed a large turnover in the last 10 years, which it claims is the result of the MDC certifications and endorsements. Alenia Aeronautics, which is a component of the larger organisation involved in defence, avionics systems and space technology, contributes over 500/4 to the group’s total operational revenue. Turnoverfor 1992 is expected to be up by 25% on the 1991 period, at $US110m.

Aside from its principal MDC conversion, Alenia is heavily involved in depot level maintenance and systems upgrades of the 18 Breguet Atlantiques and four 707s of the Italian Air Force. Two of the latter have already been converted for roles as tanker transports, with the remaining two due for delivery in 1994. The organisation also holds joint approval with Dornier from NATO for major structural inspection, overhaul and repair of the E-3A Sentry AWACS and 707 TCA aircraft.

Alenia’s Venice facility, the subsidiary Aeronavali, is located at the Marco Polo Airport, operating a 50,034m2 (538,000sq/ft) hangar area which is capable of accepting three wide body and three narrow-body aircraft simultaneously. The military aircraft maintenance and repair facilities are contained within the hangar spaces. The 700 specialised employees also devote a smaller portion of work to the manufacturing and assembly of the ‘S’ duct for the 727 re-engining program (refer p56 Sept 92 AA) the lower fuselage section of the new Breguet Atlantique 2, the G222 C-27 cargo ramp and crew doors, and the complete manufacturing of the DC-8 and DC-10 cargo conversion kits.

Aeronavali’s maintenance division provides services on narrow and wide body aircraft which include light and heavy checks, corrosion treatment and control, cabin configuration and refurbishing, fuel tank resealing and complete exterior stripping and repainting up to MD-11 size. Aeronavali was approved by the Federal Aviation Administration in 1963 as a foreign repair station