ZeAero has unveiled the ZERA-Lite, a hydrogen-powered retrofit programme for the Cessna Caravan designed to give regional operators a practical path to zero-emissions flight. The UK-based company's STC application uses its own ZERA-propulsion system, aiming to reduce the risk of entering the hydrogen market and turn the Caravan into a platform for sustainable regional operations.

The ZERA-Lite is powered by a 503kW liquid-hydrogen fuel cell system, with a maximum passenger range of around 400 nautical miles and payload capacity of about 950kg. The aircraft is intended to reduce infrastructure requirements and give operators greater network flexibility, while retaining practical cargo capacity and competitive seat-mile costs. The propulsion system is being developed for a 6,000-flight-cycle interval between major renewals.

The retrofit programme is expected to keep aircraft downtime to two to three weeks, with minimal pilot conversion required. ZeAero is in discussions with several regional operators about future deployment.

Dr Matthew Orchard, CEO of ZeAero, says: “The ZERA-Lite represents an important step towards making zero-emissions aviation a reality for regional operators and proving liquid hydrogen is a viable and profitable future vector for the whole industry. Our aim is to provide customers with a practical pathway into hydrogen-powered operations while maintaining the payload, range and operational flexibility they need.”

ZeAero is accelerating development work and preparing for its industrialisation phase, alongside engagement with certification authorities. The ZERA-Lite is targeted for entry into service by 2031.