Report: Rethinking feedstock choice is a key enabler for SAF scalability

As the aviation industry races to meet net-zero targets, sustainable aviation fuel (SAF) remains the most viable near-term solution.

But SAF producers’ reliance on a narrow set of feedstocks—especially used cooking oil (UCO)—is creating bottlenecks that threaten scalability, according to SAF market accelerator Future Energy Global and PA Consulting.

FEG and PA Consulting released a new report Oct. 13 titled “Out of the Fryer.”

The report offers a timely analysis of alternative feedstocks for hydroprocessed esters and fatty acids (HEFA)-based SAF production, highlighting the trade-offs and opportunities for airlines, SAF producers, energy players and investors.

The report explains that HEFA is the most commercially mature SAF pathway, with standalone production expected to reach 10 million metric tons globally by 2030.

The dominant feedstock, UCO, however, is facing global supply constraints.

This imbalance is driving up prices and creating uncertainty for SAF producers.

“Future Energy Global’s mission is to accelerate SAF scale-up to cut aviation emissions,” said Natasha Mann, FEG CEO and co-founder. “We’re aggregating demand to cut SAF cost to airlines. We’re pioneering book and claim to overcome logistics challenges. And now, with PA Consulting, we’re identifying future feedstocks that’ll enable SAF production to scale far beyond limited UCO supplies.”

The report identifies four alternative feedstocks widely available in the U.S.: primary oil crops like soybean and canola, oilseed cover crops, animal byproducts, and distillers’ corn oil, a byproduct of corn harvested for food or road fuel.

PA Consulting’s technical expertise helped define three key criteria for credible, scalable and sustainable feedstocks:

• Low lifecycle-GHG emissions: Feedstocks must deliver meaningful reductions compared to fossil jet fuel.

• Avoidance of market conflicts: SAF feedstocks should not compete with food or animal-feed markets. Concerns about fraud and market distortion in some UCO markets persist.

• Mature and resilient supply chains: Feedstocks with established logistics and supplier networks offer greater reliability, scalability and cost efficiency.

“If feedstock is to play its role in scaling SAF, we need credible, science-based strategies to address the bottlenecks that are limiting progress,” said Grant Gunter, energy expert at PA Consulting. “Without them, the industry risks losing momentum just as it begins to accelerate. Tackling this challenge head-on will be an important step in unlocking the next phase of sustainable aviation.”

The report is intended for airlines, energy companies, investors and other SAF stakeholders.

As HEFA production approaches its current limits, “Out of the Fryer” outlines the feedstock considerations that will shape future SAF strategies, including supply-chain reliability, emissions performance and cost implications.

For more information, click here.