FlyORO is on a quest to break barriers and redefine SAF blending

Sustainable aviation fuel (SAF) technology start-up FlyORO is in a promising position. A flurry of investments, policy changes, and technological breakthroughs in various countries is energising the nascent market for SAF, a low-carbon alternative to traditional jet fuel.

In Singapore, all flights departing the country will be required to use SAF starting in 2026. The target is one per cent SAF usage in 2026, to reach three to five per cent by 2030.

FlyORO’s standout feature is its proprietary, flexible, modular SAF blending system. Positioned at airports, it can promptly supply blended SAF to airlines and business aircraft operators, even with short notice. 

Currently, SAF is delivered in bulk, allowing producers to leverage their existing infrastructure without necessitating changes to storage tank operations. This approach ensures that each storage tank can be efficiently utilised for SAF and kerosene-based fuels. 

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However, SAFs, derived from various feedstocks like used cooking oil, animal fats and cellulosic waste, require different refining processes for each blend. This variability in fuel properties demands precise blending to meet regulatory standards for aviation fuel, posing a challenge to ensuring consistent and safe fuel quality.

Furthermore, the concept of flexible blending, which requires producers to convert storage tanks for various SAF blend ratios, presents a significant commercial hurdle in aligning with the diverse demand preferences of airlines.

This is where FlyORO’s AlphaLite system shines, according to FlyORO chief executive officer Jonathan Yeo, adding that one of the system's significant advantages is its modularity. Unlike traditional fuel companies that blend fuels at a refinery, requiring large volumes and significant lead times, AlphaLite’s on-demand blending capabilities drastically reduce lead times and enable airlines to respond quickly to market fluctuations.

"Airlines typically receive their SAF three to six months after signing an agreement. With FlyORO, as long as our system is integrated into the supply chain, we need only two to three days to blend it for you,” says Yeo. “What our technology does is that we can recognise whatever is coming in and automate the whole blend recipe to always get you to the required standard for flight.” 

This proposition eliminates the need for costly and impractical storage tank conversions and allows producers to offer both standard and bespoke SAF products to airlines without disrupting their current infrastructure. According to Yeo, this advancement enhances operational efficiency and expands the range of SAF options available to the aviation industry while offering control and flexibility to airline customers.

Unfortunately, "people have been moulded into a mindset for decades that what has been going on is the safest way to go, even though it's not the most efficient.” This entrenched mentality in the aviation industry, governed by stringent regulatory compliance, presents a significant barrier to innovation that FlyORO has encountered since its launch in 2022.

The results of innovation and resilience

FlyORO's story began in 2017 with research and development and has been marked by perseverance and ingenuity. A year before, Yeo and his two other co-founders identified a gap in the industry: the blending of SAFs. He likens the blending of SAFs to making coffee: "Just imagine that your espresso machine is standardised, but the coffee beans can come from different origins and roasting levels. The same thing applies to biofuel." 

Securing their first customer, Jet Aviation, was pivotal for FlyORO. "Getting the first customer is always gratifying," Yeo reflects, calling the achievement his proudest moment at FlyORO. “It’s about translating the concept and essence of innovation into tangible industry-wide advancements. The win bolstered our credibility.”

Later this year, FlyORO will leverage strong networks with local stakeholders to set up shop in Brisbane, Australia, partnering with an airport servicing Qantas, Virgin Australia, and Cathay Cargo. Next year, FlyORO, which raised US$1.6 million ($2.16 million) in pre-series A funding in January 2024, will establish its first flagship unit in the US.

Still, it has not been completely smooth sailing. "One venture capitalist pulled out at the last minute because their key partner believed SAF would never take off due to its higher cost," Yeo recounts. He also shared how potential customers have “brushed us off”, sending his co-founder and chief marketing officer into a funk for a few weeks each time.

These difficulties have tested the team’s resilience but also fortified them. They hold steadfast belief in their technology, keeping their spirits high as they navigate the complexities of breaking into a complex industry. "We are still in the process of facing friction and headwinds, but we are progressing."

Poised to revolutionise the SAF market

Yeo envisions FlyORO as a key player in the sustainable aviation industry in the coming decades. "The future is going to be when there's more supply coming up from various refining pathways," he says. Even though more SAF refineries are being constructed in other countries now, their completion won’t be until 2028 at the earliest. 

Meanwhile, FlyORO’s focus for the next five years is to build capability and credibility. And when 2028 arrives, “that will be the time when we are positioned to scale,” states Yeo. In time, FlyORO aims to be the leading technology enabler for airlines, providing the flexibility to choose the most economical and sustainable fuel options.

For now, fuel companies' traditional blending method remains FlyORO’s biggest competitor, and Yeo will expend his energy to “convince people that we have another solution that can also be equally compelling and much cheaper."