Postponement for greener skies: the potential for sustainable aviation fuel on-site blending at airports

Purpose Sustainable Aviation Fuel (SAF) is crucial for aviation decarbonization, but its current pre-blending process at refineries presents challenges, including fixed blending ratios, higher transportation costs and long lead times. This study explores the potential of an innovative technology that enables on-site SAF blending at airports. By postponing blending to the point of use, this approach offers customization opportunities. However, the precise benefits and trade-offs of this concept remain unclear. The research aims to assess the impact of on-site blending on fuel price, lead time, carbon emissions and supply chain costs. Design/methodology/approach This empirical study evaluates the effects of SAF postponement using case analyses of Singapore-Seletar and Maastricht airports. The analysis incorporates cost modeling, lead time assessment and carbon impact calculations to quantify the implications of shifting blending downstream to airport sites. Data sources include industry reports, airport-specific logistics information and SAF supply chain parameters. A comparative analysis is conducted to determine optimal airport conditions for SAF postponement, highlighting key enablers and barriers to implementation. Findings The results indicate that on-site SAF blending can create competitive advantages by reducing supply chain costs and lowering carbon emissions. The benefits are contingent on airport-specific factors, such as Hydroprocessed Esters and Fatty Acids availability, logistics infrastructure and regulatory conditions. The findings suggest that certain airports, particularly those with strategic locations and favorable cost structures, are better suited for adopting SAF postponement. By shifting production downstream, airports can achieve greater flexibility in SAF blending ratios while minimizing logistical inefficiencies. Originality/value To the best of the authors’ knowledge, this study is among the first to empirically examine the feasibility of postponing SAF blending to the airport level. While existing literature focuses on SAF production and distribution, the concept of downstream blending has not been systematically analyzed. The research provides new insights into how mass customization principles can be applied to SAF supply chains, potentially reshaping fuel logistics in the aviation industry. By identifying critical factors for successful implementation, this study contributes to both academic discussions and practical decision-making in sustainable aviation fuel management.