SWISS Partners with Metafuels for Synthetic SAF Supply

In a strategic move to secure future energy supplies, Swiss International Air Lines (SWISS) has announced a partnership with Zurich-based developer Metafuels. The agreement focuses on supporting the development and future offtake of synthetic aviation fuel produced from renewable methanol to jet fuel technology. This Metafuels SAF partnership is critical for SWISS's strategy to comply with the upcoming ReFuelEU Aviation mandate and achieve its ambitious decarbonization targets.

The collaboration positions SWISS, a subsidiary of the Lufthansa Group, as a key partner in advancing Metafuels' proprietary "aerobrew" technology. This Power-to-Liquid (PtL) process converts green methanol—produced from renewable electricity and captured carbon dioxide—into a drop-in jet fuel. For SWISS, the deal is a crucial step towards meeting its goal of halving net CO2 emissions by 2030 compared to 2019 levels and ensuring compliance with stringent European regulations that mandate a specific quota for synthetic fuels.

"Future availability of sustainable fuels at sufficient scale will only be possible if investments in technologies and partnerships are made today," said Jens Fehlinger, CEO of SWISS. "That is exactly what we are doing with Metafuels."

The Regulatory Imperative

The primary driver for this partnership is the ReFuelEU Aviation regulation, which has been adopted by both the European Union and Switzerland. According to the Swiss Federal Office of Civil Aviation, the mandate requires aviation fuel suppliers to blend increasing amounts of Sustainable Aviation Fuel (SAF), starting at 2% in 2025 and rising to 6% by 2030. Critically, the 2030 target includes a legally binding sub-mandate requiring that 1.2% of all jet fuel supplied must be synthetic e-SAF.

This sub-mandate for Electro-Sustainable Aviation Fuel (e-SAF) presents a significant supply chain challenge for airlines, as commercial-scale production is still in its infancy. By partnering directly with Metafuels, SWISS aims to secure a reliable supply of these mandated fuels, mitigating the risk of non-compliance penalties. However, some industry analysts have raised concerns about the feasibility of the 1.2% mandate, suggesting a potential production shortfall could force airlines to pay significant fines.

Before it can be used on commercial flights, the fuel produced by Metafuels, a type of Synthetic Paraffinic Kerosene (SPK), must first receive ASTM D7566 accreditation from ASTM International. This certification is expected in early 2026.

A Strategic Shift in SAF Procurement

The SWISS-Metafuels agreement reflects a broader industry trend where airlines are directly investing in or partnering with early-stage fuel technology companies. This strategy allows carriers to secure long-term offtake agreements ahead of anticipated supply shortages. This pattern is evident in similar moves by other major European airline groups.

In August 2023, SWISS's parent company, the Lufthansa Group, signed a letter of intent with HCS Group to procure SAF made via an Alcohol-to-Jet pathway starting in 2026. Similarly, in October 2022, Air France-KLM invested in DG Fuels to secure up to 21 million gallons of synthetic SAF annually. These precedents show that major European carriers are proactively building their own SAF supply chains rather than relying solely on traditional energy suppliers.

"If sustainable aviation fuel is to become a true alternative to fossil jet fuel, it has to work at an industrial scale and competitive cost," stated Saurabh Kapoor, CEO of Metafuels. "Methanol-to-jet makes that possible."

Methanol-to-Jet vs. HEFA SAF

The industry's focus is increasingly shifting from first-generation HEFA (Hydroprocessed Esters and Fatty Acids) SAF to advanced pathways like Power-to-Liquid. While HEFA has dominated the SAF market to date, its growth is constrained by the limited global supply of its feedstocks, primarily used cooking oil and animal fats. In contrast, e-SAF is considered highly scalable.

This scalability is a key reason airlines like SWISS are investing in PtL technologies, despite their current higher cost and the immense renewable electricity required for production—a point of concern for some environmental groups who argue it could divert clean energy from other sectors.

What Comes Next

Metafuels has a clear roadmap for scaling its production. According to its official project timeline, the company expects to begin operating a pilot plant at the Paul Scherrer Institute in Switzerland in early 2025. Following successful ASTM accreditation in early 2026, the first commercial-scale plant, named 'Turbe', is planned for the Port of Rotterdam.

This facility is slated to begin operations in 2028, with an initial production capacity of 10 tons of e-SAF per day. The project roadmap outlines a rapid scaling to 100 tons per day by 2031. These volumes will be critical for SWISS and other airlines to meet the ReFuelEU mandate, which becomes effective on January 1, 2030.

Why This Matters

This partnership is more than a fuel supply agreement; it represents a foundational investment in the future of aviation energy. For SWISS, it de-risks its path to regulatory compliance and supports its publicly stated environmental targets. For the industry, it serves as a powerful signal that airlines are no longer passive consumers of fuel but are becoming active participants in building the complex, capital-intensive supply chains required for decarbonization. The success of such partnerships will be essential to transforming ambitious mandates into tangible carbon reductions.