Crashed UPS MD-11 Was Part of Aging Fleet with Costly Legacy

The UPS jet involved in the deadly Kentucky crash was part of a fleet of aging McDonnell Douglas MD-11 aircraft long known for their high operating costs and complex handling. Once a staple of long-haul passenger travel, the MD-11 has not flown passengers since 2014 but remains in service as a cargo workhorse for carriers such as UPS, FedEx, and Western Global Airlines.

First introduced in 1990 as a wide-body passenger jet, the MD-11 was intended to modernize air travel with greater range and capacity. However, its high fuel consumption and steep maintenance costs quickly made it economically unviable for commercial airlines. “The model was antiquated by the time it came out – except, of course, for cargo. It’s a workhorse,” said Mary Schiavo, former U.S. Department of Transportation Inspector General. “It’s a big, heavy aircraft.”

While the MD-11 has faced its share of safety incidents over the decades, experts say its biggest challenge has always been economics rather than safety. “It’s economics,” said John Cox, founder of Safety Operating Systems and longtime USA TODAY aviation columnist. “The airplanes are an older design. They’re not as fuel-efficient. They require more maintenance than later generation airplanes.”

As of late 2025, there are around 40 to 50 MD-11 freighters still in operation worldwide, FedEx Express operates the largest number, followed by UPS and Western Global Airlines. Both FedEx and UPS had already planned to phase out the tri-jet in favor of newer, more efficient Boeing 767-300ERF and 777-200LRF models before the Louisville tragedy.

The National Transportation Safety Board (NTSB) dispatched a 28-member investigative team to Louisville to determine the cause of the crash, working in coordination with the Federal Aviation Administration (FAA).

The Decline of the MD-11

Passenger airlines began retiring the MD-11 long before its cargo phase-out commenced. The last commercial carrier to operate the type was KLM, which retired its final passenger MD-11 in 2014, citing high operating costs and challenges sourcing parts. “The aircraft was expensive to maintain, had high fuel consumption, and spare parts were hard to find,” KLM noted in its final statement about the aircraft. Swissair—now Swiss International Air Lines—echoed similar concerns during its own retirement of the MD-11 from passenger service.

Experts agree that the MD-11’s demise was driven primarily by cost and complexity. “In general, the economics of an aircraft dictates how long they keep it in service,” said Ross “Rusty” Aimer, CEO of Aero Consulting Experts and a former United Airlines pilot. Aimer noted that the aircraft also had a reputation among pilots as being challenging to land. “It had kind of a reputation of being a hard airplane to land,” he said.

Aviation attorney Daniel Rose of Kreindler & Kreindler echoed that sentiment, emphasizing that MD-11s were simply too expensive to operate. “They were retired from passenger service because they were too expensive in terms of fuel and maintenance,” he said. Fellow aviation lawyer Ladd Sanger added that age is now a critical factor: “Aircraft have a useful life – and these are all 30-plus years old, some 40 years old, and they’re nearing the end of it.”

McDonnell Douglas produced only 200 MD-11s before discontinuing the line in 2000, according to Simple Flying. As of late 2025, there are approximately 40 to 50 McDonnell Douglas MD-11 aircraft still active in service, all operating as freighters.

MD-11 Active Fleet Snapshot (2025)

• FedEx Express: Operates the largest MD-11 fleet, with 74 aircraft, though many are being gradually retired and replaced by Boeing 767 and 777 freighters.
  Converted MD-11s from passenger use: American Airlines, Delta Air Lines, Swissair, and KLM.
  FedEx also received some MD-11Fs directly from McDonnell Douglas as freighters.
  
• UPS Airlines: Operates 43 MD-11s, with 28 still active as of late 2025.
  Converted MD-11s from passenger use: Varig, Alitalia, China Eastern, and Thai Airways.
  UPS also acquired MD-11s from Lufthansa Cargo after their retirement in 2021.
  
• Western Global Airlines: Operates 17 MD-11s, but only 2 are currently active.
  Converted MD-11s from passenger use: Finnair, Japan Airlines, and Martinair.
  Many of these were acquired secondhand from other cargo operators like Lufthansa and World Airways.

Decline in Active Use

• The MD-11 is no longer used for passenger service; its last commercial passenger flight was in 2014.
• Following a recent fatal crash involving a UPS MD-11, Boeing has recommended that all operators temporarily ground the aircraft pending further investigation.
• The aircraft’s age, fuel inefficiency, and maintenance costs have accelerated its retirement from most fleets.

Safety Record and Past Incidents

Despite being a cargo workhorse, the MD-11 has a checkered safety history—much like the aircraft it was based on, the McDonnell Douglas DC-10. The DC-10 was succeeded by the MD-11, which offered improved range and efficiency. Many DC-10s were later converted to freighters or upgraded to MD-10s with modern avionics. A total of 386 DC-10 aircraft were produced between 1968 and 1989. According to the NTSB, there have been only two other major incidents involving MD-11s in the past decade, both operated by UPS.

In 2016, a UPS MD-11 overran the runway during a rejected takeoff at Seoul’s Incheon International Airport, ending nose-down in the grass. Injuries were minor, but the aircraft was heavily damaged. In 2021, another UPS MD-11 departing Louisville experienced a tailstrike while landing at Phoenix Sky Harbor International Airport. The crew circled back and landed safely, though the plane sustained substantial structural damage to its rear fuselage and pressure bulkhead.

Earlier incidents were more tragic. In 2009, a FedEx MD-11 crashed during landing at Tokyo Narita International Airport, killing both pilots. Later that same year, an Avient Aviation MD-11 crashed during takeoff in Shanghai, killing three crew members.

The McDonnell Douglas MD-11 experienced several notable passenger aircraft incidents before its retirement from commercial service. The most tragic was Swissair Flight 111 in 1998, which crashed off the coast of Nova Scotia due to an onboard fire, killing all 229 people. In 1999, China Airlines Flight 642 crashed during landing in typhoon conditions in Hong Kong, resulting in 3 fatalities out of 315 onboard. Earlier, in 1993, China Eastern Flight 583 suffered an in-flight upset due to accidental slat deployment, causing 2 passenger deaths. These incidents, combined with the MD-11’s reputation for challenging landings and fuel inefficiency, contributed to its phase-out from passenger service, with the last scheduled flight operated by KLM in 2014.

Following the decision by UPS and FedEx to temporarily ground their MD-11 fleets after the fatal UPS crash in Louisville, experts suggest that this coordinated response may accelerate the retirement of aging tri-jet aircraft. In their place, carriers are expected to adopt newer, more fuel-efficient twin-engine models with advanced technology. This shift reflects a broader industry trend toward fleet modernization to meet evolving standards in safety, sustainability, and performance.

As the investigation into the Louisville crash continues, both UPS and FedEx have pledged full transparency and cooperation with authorities. The incident underscores a sobering truth: in aviation, safety is non-negotiable. Insights gained from this tragedy are expected to influence future fleet decisions and reaffirm the industry’s commitment to ensuring that every flight—whether transporting passengers or cargo—adheres to the highest safety protocols.

With mounting operational costs and a history of safety concerns, the MD-11’s legacy is increasingly complex. Once a pioneering force in long-haul cargo transport, it now stands as a cautionary emblem of the challenges posed by aging aircraft in a rapidly advancing aviation landscape.


Related News: https://airguide.info/?s=UPS, https://airguide.info/?s=MD-11, https://airguide.info/category/air-travel-business/travel-health-security/

Sources: AirGuide Business airguide.info, bing.com, usatoday.com