Why Airlines still spend up to $40,000 an hour to keep the Boeing 747 Flying

Despite its gradual disappearance from passenger fleets, the Boeing 747 remains a major workhorse for global cargo airlines, even as operating the iconic jumbo jet can cost between $20,000 and $40,000 per block hour in 2026.

The wide variation depends on whether airlines are measuring direct operating costs or charter pricing, with scheduled Boeing 747-400 and Boeing 747-8 operations typically costing between $20,000 and $30,000 per block hour, while one-off charter flights can approach $40,000 per hour, according to aviation industry estimates.

Fuel Costs Drive Airline Operating Expenses

Fuel continues to account for the largest share of a Boeing 747’s operating costs.

A Boeing 747-400 burns approximately 3,240 gallons (12,265 litres) of fuel every hour during cruise. With average jet fuel prices forecast at $152 per barrel in 2026 following supply disruptions linked to the closure of the Strait of Hormuz, the aircraft’s hourly fuel bill alone can exceed $10,000.

Industry analysts note that fuel consumption varies throughout a flight, with take-off and climb requiring significantly more fuel than cruise or descent. Aircraft weight, weather conditions, routing restrictions and airport congestion also influence total fuel use.

Maintenance and Crew Increase Operating Costs

Beyond fuel, airlines face substantial expenses from flight crews, maintenance, airport charges, air traffic control fees and ground handling.

A Boeing 747 requires a minimum of two pilots, with additional flight crew required on longer flights, alongside at least 12 cabin crew under regulatory requirements. Maintenance costs also remain high because the aircraft’s four engines require separate inspection, overhaul and repair programmes.

Operators with dedicated engineering capabilities and long-term maintenance contracts are generally better positioned to control these expenses than smaller operators.

Freight Market Keeps the Jumbo Relevant

While passenger airlines have largely replaced the Boeing 747 with more fuel-efficient twin-engine aircraft, cargo operators continue to find strong commercial value in the aircraft.

Its large payload capacity and nose-loading capability enable freight airlines to spread high operating costs across larger cargo volumes, helping maintain profitability.

Strong cargo demand has also encouraged some operators to return retired Boeing 747s from long-term storage to commercial service after extensive maintenance work.

Although the global Boeing 747 fleet continues to shrink, limited spare parts, constrained overhaul capacity and fewer qualified engineers continue to keep maintenance costs elevated, reinforcing the aircraft’s reputation as one of aviation’s most expensive, but still commercially valuable, assets.

Read also: Boeing’s $715bn order backlog signals strong recovery despite operating loss