We went aboard Boeing's largest twin-engine cargo plane and saw how it's tackling the shipping crisis from the air

Thomas PalliniJan 11, 2022, 18:44 IST

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Air cargo has seen a surge in popularity thanks to a crisis in ocean shipping.
Emirates SkyCargo is one of the airlines using a fleet of dedicated freighters to get goods to market.

The crisis in ocean shipping is seeing companies look to the skies for a faster way to get their goods to market, even if it means paying more.

Touring the Ports of Los Angeles and Long Beach.Thomas Pallini/Insider

Cargo planes are quite literally flying over port congestion with cargo carriers and passenger airlines alike cashing in on the new shipping trends.

Israel Aerospace Industries' Boeing 777-300ER "Big Twin" cargo plane.Israel Aerospace Industries

The Boeing 777 Freighter is one of the aircraft on the front lines of the airfreight industry as one of the newest and largest cargo planes in the skies.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Boeing has sold more than 300 777 Freighters and many of the airlines flying the passenger version of the aircraft have also ordered it for their cargo divisions, including Middle Eastern mega carrier Emirates.

An Emirates SkyCargo Boeing 777-200 Freighter.Carlos Yudica / Shutterstock.com

Boeing has sold more than 300 777 Freighters and many of the airlines flying the passenger version of the aircraft have also ordered it for their cargo divisions, including Middle Eastern mega carrier Emirates.

Emirates operates a fleet of 10 Boeing 777 Freighters under its SkyCargo division alongside its sprawling fleet. Each aircraft can carry 107,000 kilograms, or around 235,894 pounds, of cargo.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Emirates operates a fleet of 10 Boeing 777 Freighters under its SkyCargo division alongside its sprawling fleet. Each aircraft can carry 107,000 kilograms, or around 235,894 pounds, of cargo.

We went on board an Emirates SkyCargo Boeing 777 Freighter in Dubai to see how one of the world's most popular passenger jets has a successful second life as a cargo plane. Here's what it was like.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

We went on board an Emirates SkyCargo Boeing 777 Freighter in Dubai to see how one of the world's most popular passenger jets has a successful second life as a cargo plane. Here's what it was like.

Away from the glitzy passenger terminals of Dubai International Airport sits cargo village, home to Emirates SkyCargo. Cargo from around the world passes through Dubai every day on a mix of cargo planes and in the belly of passenger aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Away from the glitzy passenger terminals of Dubai International Airport sits cargo village, home to Emirates SkyCargo. Cargo from around the world passes through Dubai every day on a mix of cargo planes and in the belly of passenger aircraft.

This Boeing 777 Freighter arrived in Dubai from Hong Kong, one important cargo destination in what Emirates calls the "world's factory." From Hong Kong, cargo can be in any one of Emirates destinations in a day, depending on flight schedules, just as a passenger can.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

This Boeing 777 Freighter arrived in Dubai from Hong Kong, one important cargo destination in what Emirates calls the "world's factory." From Hong Kong, cargo can be in any one of Emirates destinations in a day, depending on flight schedules, just as a passenger can.

As soon as the aircraft pulled into its stand, a team of ground handlers descended on the plane just as they would if this was an Emirates passenger flight. Airstairs were brought to the front of the plane to allow the crew to deplane while cargo loaders focused on the rest of the aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

As soon as the aircraft pulled into its stand, a team of ground handlers descended on the plane just as they would if this was an Emirates passenger flight. Airstairs were brought to the front of the plane to allow the crew to deplane while cargo loaders focused on the rest of the aircraft.

Around 80% of goods that arrive in Dubai on Emirates planes will continue to further destinations while the rest will stay in the city.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The Boeing 777 Freighter has one giant door on its upper deck and three doors on its lower deck: two for large cargo pallets and one for smaller boxes.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Weight and balance concerns dictate the loading and unloading of the aircraft. Freight handlers focus first on offloading the rear of the aircraft and cargo loaders start by unloading the upper and lower cargo holds simultaneously.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Weight and balance concerns dictate the loading and unloading of the aircraft. Freight handlers focus first on offloading the rear of the aircraft and cargo loaders start by unloading the upper and lower cargo holds simultaneously.

It takes around 30 seconds for cargo to be lowered from the upper deck to the tarmac, where it’s then pushed onto a dolly as part of a “dolly train.”

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The upper deck of the Boeing 777 Freighter can store 6,800 kilograms of freight per pallet. Each aircraft requires around 10 ground handlers to service, with heavy machinery doing most of the heavy lifting.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The upper deck of the Boeing 777 Freighter can store 6,800 kilograms of freight per pallet. Each aircraft requires around 10 ground handlers to service, with heavy machinery doing most of the heavy lifting.

Loose boxes, almost like luggage coming off a passenger aircraft, still need to be manually offloaded and stacked by handlers, however.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The front half of the aircraft is offloaded last to keep the plane balanced throughout the process.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Lower deck pallets are smaller than those found on the upper deck and can only hold a maximum of 5,000 kilograms per pallet.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Climbing on board the aircraft, there are no flight attendants greeting passengers at the door; rather, no flight attendants at all. These dedicated freighter aircraft are designed to fly solely with pilots onboard.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Climbing on board the aircraft, there are no flight attendants greeting passengers at the door; rather, no flight attendants at all. These dedicated freighter aircraft are designed to fly solely with pilots onboard.

Instead of the 266 seats that would normally fill an Emirates aircraft of this size, only nine fill the small compartment between the cockpit and the cargo hold.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The seats are also far from what is found on Emirates' passenger aircraft but do come with some amenities including power outlets and access to a galley full of beverages. Pilots also have access to a crew rest area with bunk beds for long-haul flights.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The seats are also far from what is found on Emirates' passenger aircraft but do come with some amenities including power outlets and access to a galley full of beverages. Pilots also have access to a crew rest area with bunk beds for long-haul flights.

A loadmaster or a person accompanying a piece of cargo may join the flight but only if circumstances require.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

With no flight attendants onboard, it's up to pilots to craft and heat their own meals using the onboard galley.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Emirates caters the aircraft with crew meals, just as it would any other flight.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

When departing from Dubai, Emirates Flight Catering is tasked with ensuring that flights are well-stocked before each departure.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Separating the cockpit and passenger compartment from the cargo hold is a rigid barrier that protects the cockpit should cargo unexpectedly shift during flight.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Two openings allow pilots to access the cargo hold should the need arise.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

It's nothing but empty space in the cargo hold from the rigid barrier all the way down to the tail. The glitzy first class suites for which Emirates is known are nowhere to be found in this aircraft cabin.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

It's nothing but empty space in the cargo hold from the rigid barrier all the way down to the tail. The glitzy first class suites for which Emirates is known are nowhere to be found in this aircraft cabin.

As many as 27 pallets measuring 96 inches wide by 125 inches tall can be stored in the upper deck cargo hold in a 1-1 configuration.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

And with no passengers onboard, there is no need for windows in the aircraft. Rather, two small porthole-like windows let pilots check on the engines.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

All cargo on the upper deck is loaded through the read cargo door, measuring 142 inches wide by 120 inches tall.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The size of the door allows Emirates to carry unique cargo on the upper deck including luxury cars and even racehorses.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Each pallet can be stacked as high as three meters and boxes are stacked to match the curvature of the aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Back in Emirates’ cargo warehouse, workers use frames based on the curvature of the aircraft to ensure that pallets will fit inside the aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Freight is also covered in waterproof tarps, as well as netting, to keep it protected while in transit.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Cargo bound for the lower deck of aircraft is stacked in a rectangular shape or put into containers that are then loaded onto the aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Once inside the aircraft, tracks are opened so that the pallets can be moved throughout the aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Small wheels on the ground make it so that ground handlers can easily and efficiently move pallets to their assigned locations on the aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Pallets, just like passengers, have assigned seating spots on the aircraft so handlers know exactly where to place each one.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Each section of the aircraft is labeled along the cabin wall, almost like a row and seat number for pallets.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Local control panels can be found along the cabin walls that move pallets within a given section.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Cameras throughout the interior and exterior of the aircraft allow pilots to keep an eye on the cargo as it's being loaded and offloaded, as well as while it's in flight.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Cameras throughout the interior and exterior of the aircraft allow pilots to keep an eye on the cargo as it's being loaded and offloaded, as well as while it's in flight.

And once a pallet is at its assigned section, ground handlers lock them into place so they don't shift during flight.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The cabin floor is also reinforced which allows the upper deck of the aircraft to carry heavier freight loads than traditional passenger aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Sometimes, even packages can miss their flights. Emirates SkyCargo uses the metric "flown as booked" to gauge the on-time performance of its packages.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Much like in the passenger realm, Emirates will work to ensure that packages make it onto the aircraft on which they are booked. If a package misses its flight, staff will have to identify why and ensure that alternate arrangements are made.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Much like in the passenger realm, Emirates will work to ensure that packages make it onto the aircraft on which they are booked. If a package misses its flight, staff will have to identify why and ensure that alternate arrangements are made.

Freight will also never take precedence over passengers when passenger aircraft are being used. If cargo is holding up an on-time departure, it's likely that the cargo will have to take the next flight; though, there is some leeway with dedicated freighters.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Freight will also never take precedence over passengers when passenger aircraft are being used. If cargo is holding up an on-time departure, it's likely that the cargo will have to take the next flight; though, there is some leeway with dedicated freighters.

Some of the most important cargo over the past year has been the COVID-19 vaccine. Emirates SkyCargo was among the first airlines to transport the vaccine, and still handles shipments today.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Some of the most important cargo over the past year has been the COVID-19 vaccine. Emirates SkyCargo was among the first airlines to transport the vaccine, and still handles shipments today.

Cold storage containers help keep the vaccines cool in the Dubai heat so that they don't spoil.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Emirates even expanded its "skypharma" facilities to include cold storage sections with temperatures ranging between two degrees Celsius and 25 degrees Celsius.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

The Boeing 777 is a favorite among cargo carriers thanks to its range and efficiency compared to older model aircraft.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Emirates routinely flies long-haul flights between cargo hubs like Zaragoza, Spain and Mexico City, Mexico; Dubai and London; and Singapore and Sydney.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

More Boeing 777 Freighters are on their way to Emirates Sky Cargo thanks to a recent order for two aircraft at the Dubai Airshow in November.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

Emirates has also committed to converting four of its Boeing 777-300ER passenger aircraft into cargo planes in a deal with Israel Aerospace Industries.

An Emirates Boeing 777-300ER.JetKat/Shutterstock

Known as the "Big Twin," the 777-300ER will be the largest twin-engine cargo plane in the skies once certified in 2023.

Israel Aerospace Industries' Boeing 777-300ER "Big Twin" cargo plane.Israel Aerospace Industries

It's a billion-dollar bet that Emirates is making that the air cargo boom will last at least through the decade. And more carriers, recognizing the value in air cargo, are starting to do the same.

Touring the Emirates SkyCargo operation in Dubai.Thomas Pallini/Insider

It's a billion-dollar bet that Emirates is making that the air cargo boom will last at least through the decade. And more carriers, recognizing the value in air cargo, are starting to do the same.

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We went aboard Boeing's largest twin-engine cargo plane and saw how it's tackling the shipping crisis from the air

The crisis in ocean shipping is seeing companies look to the skies for a faster way to get their goods to market, even if it means paying more.

Cargo planes are quite literally flying over port congestion with cargo carriers and passenger airlines alike cashing in on the new shipping trends.

The Boeing 777 Freighter is one of the aircraft on the front lines of the airfreight industry as one of the newest and largest cargo planes in the skies.

Boeing has sold more than 300 777 Freighters and many of the airlines flying the passenger version of the aircraft have also ordered it for their cargo divisions, including Middle Eastern mega carrier Emirates.

Emirates operates a fleet of 10 Boeing 777 Freighters under its SkyCargo division alongside its sprawling fleet. Each aircraft can carry 107,000 kilograms, or around 235,894 pounds, of cargo.

We went on board an Emirates SkyCargo Boeing 777 Freighter in Dubai to see how one of the world's most popular passenger jets has a successful second life as a cargo plane. Here's what it was like.

Away from the glitzy passenger terminals of Dubai International Airport sits cargo village, home to Emirates SkyCargo. Cargo from around the world passes through Dubai every day on a mix of cargo planes and in the belly of passenger aircraft.

This Boeing 777 Freighter arrived in Dubai from Hong Kong, one important cargo destination in what Emirates calls the "world's factory." From Hong Kong, cargo can be in any one of Emirates destinations in a day, depending on flight schedules, just as a passenger can.

As soon as the aircraft pulled into its stand, a team of ground handlers descended on the plane just as they would if this was an Emirates passenger flight. Airstairs were brought to the front of the plane to allow the crew to deplane while cargo loaders focused on the rest of the aircraft.

Around 80% of goods that arrive in Dubai on Emirates planes will continue to further destinations while the rest will stay in the city.

The Boeing 777 Freighter has one giant door on its upper deck and three doors on its lower deck: two for large cargo pallets and one for smaller boxes.

Weight and balance concerns dictate the loading and unloading of the aircraft. Freight handlers focus first on offloading the rear of the aircraft and cargo loaders start by unloading the upper and lower cargo holds simultaneously.

It takes around 30 seconds for cargo to be lowered from the upper deck to the tarmac, where it’s then pushed onto a dolly as part of a “dolly train.”

The upper deck of the Boeing 777 Freighter can store 6,800 kilograms of freight per pallet. Each aircraft requires around 10 ground handlers to service, with heavy machinery doing most of the heavy lifting.

Loose boxes, almost like luggage coming off a passenger aircraft, still need to be manually offloaded and stacked by handlers, however.

The front half of the aircraft is offloaded last to keep the plane balanced throughout the process.

Lower deck pallets are smaller than those found on the upper deck and can only hold a maximum of 5,000 kilograms per pallet.

Climbing on board the aircraft, there are no flight attendants greeting passengers at the door; rather, no flight attendants at all. These dedicated freighter aircraft are designed to fly solely with pilots onboard.

Instead of the 266 seats that would normally fill an Emirates aircraft of this size, only nine fill the small compartment between the cockpit and the cargo hold.

The seats are also far from what is found on Emirates' passenger aircraft but do come with some amenities including power outlets and access to a galley full of beverages. Pilots also have access to a crew rest area with bunk beds for long-haul flights.

A loadmaster or a person accompanying a piece of cargo may join the flight but only if circumstances require.

With no flight attendants onboard, it's up to pilots to craft and heat their own meals using the onboard galley.

Emirates caters the aircraft with crew meals, just as it would any other flight.

When departing from Dubai, Emirates Flight Catering is tasked with ensuring that flights are well-stocked before each departure.

Separating the cockpit and passenger compartment from the cargo hold is a rigid barrier that protects the cockpit should cargo unexpectedly shift during flight.

Two openings allow pilots to access the cargo hold should the need arise.

It's nothing but empty space in the cargo hold from the rigid barrier all the way down to the tail. The glitzy first class suites for which Emirates is known are nowhere to be found in this aircraft cabin.

As many as 27 pallets measuring 96 inches wide by 125 inches tall can be stored in the upper deck cargo hold in a 1-1 configuration.

And with no passengers onboard, there is no need for windows in the aircraft. Rather, two small porthole-like windows let pilots check on the engines.

All cargo on the upper deck is loaded through the read cargo door, measuring 142 inches wide by 120 inches tall.

The size of the door allows Emirates to carry unique cargo on the upper deck including luxury cars and even racehorses.

Each pallet can be stacked as high as three meters and boxes are stacked to match the curvature of the aircraft.

Back in Emirates’ cargo warehouse, workers use frames based on the curvature of the aircraft to ensure that pallets will fit inside the aircraft.

Freight is also covered in waterproof tarps, as well as netting, to keep it protected while in transit.

Cargo bound for the lower deck of aircraft is stacked in a rectangular shape or put into containers that are then loaded onto the aircraft.

Once inside the aircraft, tracks are opened so that the pallets can be moved throughout the aircraft.

Small wheels on the ground make it so that ground handlers can easily and efficiently move pallets to their assigned locations on the aircraft.

Pallets, just like passengers, have assigned seating spots on the aircraft so handlers know exactly where to place each one.

Each section of the aircraft is labeled along the cabin wall, almost like a row and seat number for pallets.

Local control panels can be found along the cabin walls that move pallets within a given section.

Cameras throughout the interior and exterior of the aircraft allow pilots to keep an eye on the cargo as it's being loaded and offloaded, as well as while it's in flight.

And once a pallet is at its assigned section, ground handlers lock them into place so they don't shift during flight.

The cabin floor is also reinforced which allows the upper deck of the aircraft to carry heavier freight loads than traditional passenger aircraft.

Sometimes, even packages can miss their flights. Emirates SkyCargo uses the metric "flown as booked" to gauge the on-time performance of its packages.

Much like in the passenger realm, Emirates will work to ensure that packages make it onto the aircraft on which they are booked. If a package misses its flight, staff will have to identify why and ensure that alternate arrangements are made.

Freight will also never take precedence over passengers when passenger aircraft are being used. If cargo is holding up an on-time departure, it's likely that the cargo will have to take the next flight; though, there is some leeway with dedicated freighters.

Some of the most important cargo over the past year has been the COVID-19 vaccine. Emirates SkyCargo was among the first airlines to transport the vaccine, and still handles shipments today.

Cold storage containers help keep the vaccines cool in the Dubai heat so that they don't spoil.

Emirates even expanded its "skypharma" facilities to include cold storage sections with temperatures ranging between two degrees Celsius and 25 degrees Celsius.

The Boeing 777 is a favorite among cargo carriers thanks to its range and efficiency compared to older model aircraft.

Emirates routinely flies long-haul flights between cargo hubs like Zaragoza, Spain and Mexico City, Mexico; Dubai and London; and Singapore and Sydney.

More Boeing 777 Freighters are on their way to Emirates Sky Cargo thanks to a recent order for two aircraft at the Dubai Airshow in November.

Emirates has also committed to converting four of its Boeing 777-300ER passenger aircraft into cargo planes in a deal with Israel Aerospace Industries.

Known as the "Big Twin," the 777-300ER will be the largest twin-engine cargo plane in the skies once certified in 2023.

It's a billion-dollar bet that Emirates is making that the air cargo boom will last at least through the decade. And more carriers, recognizing the value in air cargo, are starting to do the same.