AIRCO™ Deploys AIRMADE® Fuel Plant in New York, Advancing Scalable CO₂-to-Fuel Production
AIRCO™, a carbon conversion technology company dedicated to transforming captured carbon dioxide into essential fuels, has officially announced the successful operation of its new integrated AIRMADE® Fuel plant in Brooklyn, New York. This milestone marks a significant step forward not only for AIRCO itself but also for the broader clean energy sector, as the world moves toward scalable synthetic fuel solutions capable of decarbonizing hard-to-abate industries such as aviation and aerospace.
The deployment of the AIRMADE® Fuel plant represents the culmination of years of research, design, and strategic investment. By bringing together the core components of its proprietary carbon-to-fuel technology into one fully integrated system, AIRCO is demonstrating the technical viability of producing sustainable fuel at scale. Supported by its $70 million Series B capital raise, the company is now able to showcase how modular, flexible, and mobile technology can reliably convert carbon emissions into high-value, low-carbon fuels.
A Two-Stage Conversion Process
At the center of the AIRMADE® Fuel plant is AIRCO’s proprietary process that converts captured CO₂ and clean hydrogen into fuel-grade synthesis gas, which is then upgraded into liquid fuel intermediates. This system operates as a continuous, integrated two-part process:
- Initial Conversion Stage – AIRCO’s AIRMADE™ technology transforms carbon dioxide and hydrogen into essential building blocks for liquid fuel.
- Fuel Optimization Stage – These intermediates undergo additional upgrading and refinement, resulting in a highly optimized fuel blending component suitable for jet fuel and other aerospace applications.
By combining these once-separate steps into a single operational plant, AIRCO has achieved a critical proof point for commercial scalability. This integration demonstrates that synthetic fuel production can be streamlined, reliable, and adaptable, paving the way for larger-scale deployments in the near future.
Strategic Role of the United States
The Brooklyn facility also underscores AIRCO’s commitment to the United States as a proving ground for next-generation carbon technologies. “The United States will remain a critical proving ground and home for our technology,” said Gregory Constantine, Co-Founder and CEO of AIRCO. “The successful operation of this plant marks another step toward our vision of commercializing multiple carbon technologies. It demonstrates how a variety of feedstocks, including captured carbon, can be transformed into synthetic fuels that can be scaled to meet growing global demand.”
The U.S. aviation industry, which faces enormous challenges in meeting net-zero targets by mid-century, represents one of the largest potential markets for synthetic fuel. By situating its demonstration plant in New York, AIRCO is positioning itself at the heart of a global transportation hub while also aligning with government-led decarbonization initiatives.
Testing, Validation, and Industry Standards
One of the most important functions of the AIRMADE® Fuel plant will be testing and validation. Synthetic fuel must meet rigorous safety and performance standards before it can be adopted at commercial scale, particularly in the aviation and defense sectors. The Brooklyn site allows AIRCO to run real-world demonstrations of its fuel components, gathering data to ensure that its outputs not only match but potentially exceed the quality of conventional jet fuel.
This testing phase is essential for securing regulatory approvals, scaling partnerships, and ultimately accelerating commercial adoption. By demonstrating compliance with stringent industry standards, AIRCO strengthens the case for synthetic fuels as a viable pathway toward decarbonizing aviation, one of the most emissions-intensive industries worldwide.
Modular, Mobile, and Scalable Design
A distinguishing feature of the AIRMADE® Fuel plant is its modular and mobile design philosophy. Unlike traditional fuel refineries, which require massive, centralized infrastructure, AIRCO’s technology can be deployed in a variety of settings and adapted to local feedstocks and energy sources. This flexibility enables installations near industrial CO₂ emitters, renewable energy hubs, or even defense-related operations requiring secure and localized fuel production.
The system is designed to integrate with multiple clean energy sources, whether powered by renewable electricity, nuclear energy, or advanced hydrogen production technologies. This adaptability enhances the resilience of the process and increases its relevance to diverse markets worldwide.
Building Partnerships Across Industries
The commissioning of the AIRMADE® Fuel plant also signals AIRCO’s growing role across both the defense and commercial aviation sectors. The company has ongoing collaborations with the U.S. Department of Defense to explore how carbon-to-fuel technologies could support energy security and reduce military reliance on fossil-based supply chains.
At the same time, AIRCO is working with major commercial aviation partners, including JetBlue and Virgin Atlantic, to advance the adoption of synthetic fuels in passenger air travel. These partnerships are particularly crucial, as airlines face increasing regulatory and consumer pressure to reduce their carbon footprints while maintaining performance and safety standards.
By positioning itself at the intersection of government-backed innovation and private-sector adoption, AIRCO is building a robust pathway toward scaling its technology and driving real-world impact.
A Broader Vision for Carbon Utilization
The AIRMADE® Fuel plant represents just one piece of AIRCO’s broader mission: turning waste carbon into valuable resources. Beyond aviation fuel, the company envisions applications across multiple industries where carbon-derived products can replace fossil-based equivalents, ranging from chemicals to consumer goods.
This vision is rooted in the belief that captured CO₂ should not be seen solely as a waste product but as a valuable feedstock for sustainable production. By converting carbon emissions into usable fuels and materials, AIRCO is helping to close the loop on carbon, reducing reliance on fossil extraction, and accelerating the transition to a circular carbon economy.
