Rethinking feedstock choice is a key enabler for SAF scalability, says new report from Future Energy Global and PA Consulting

LONDON, UK, and DUBLIN, IRELAND – 13 OCTOBER, 2025

 

As the aviation industry races to meet net zero targets, sustainable aviation fuel (SAF) remains the most viable near-term solution. But SAF producers’ reliance on a narrow set of feedstocks – especially used cooking oil (UCO) – is creating bottlenecks that threaten scalability.

 

Future Energy Global (FEG), a pioneering SAF market accelerator, and PA Consulting, the global innovation and transformation consultancy, today released a new report titled Out of the Fryer. The report offers a timely analysis of alternative feedstocks for HEFA-based SAF production, highlighting the trade-offs and opportunities for airlines, SAF producers, energy players, and investors.

 

The report explains that HEFA (Hydroprocessed Esters and Fatty Acids) is the most commercially mature SAF pathway, with standalone production expected to reach 10 million metric tons globally by 2030.

 

However, the dominant feedstock – Used Cooking Oil – is facing global supply constraints.

This imbalance is driving up prices and creating uncertainty for SAF producers.

 

“Future Energy Global’s mission is to accelerate SAF scale-up to cut aviation emissions,” said Natasha Mann, FEG CEO and Co-Founder. “We’re aggregating demand to cut SAF cost to airlines. We’re pioneering Book and Claim to overcome logistics challenges. And now, with PA Consulting, we’re identifying future feedstocks that’ll enable SAF production to scale far beyond limited Used Cooking Oil supplies.”

 

The report identifies four alternative feedstocks widely available in the US: primary oil crops like soybean and canola; oilseed cover crops; animal by-products; and distillers’ corn oil, a by-product of corn harvested for food or road fuel.

 

PA Consulting’s technical expertise helped define three key criteria for credible, scalable and sustainable feedstocks:

 

• Low lifecycle GHG emissions: Feedstocks must deliver meaningful reductions compared to fossil jet fuel.

• Avoidance of market conflicts: SAF feedstocks should not compete with food or animal feed markets. Concerns about fraud and market distortion in some UCO markets persist.

• Mature and resilient supply chains: Feedstocks with established logistics and supplier networks offer greater reliability, scalability, and cost efficiency.

 

Grant Gunter, Energy Expert at PA Consulting, said: “If feedstock is to play its role in scaling SAF, we need credible, science-based strategies to address the bottlenecks which are limiting progress. Without them, the industry risks losing momentum just as it begins to accelerate. Tackling this challenge head-on will be an important step in unlocking the next phase of sustainable aviation.”

 

The report is intended for airlines, energy companies, investors, and other SAF stakeholders. As HEFA production approaches its current limits, Out of the Fryer outlines the feedstock considerations that will shape future SAF strategies, including supply chain reliability, emissions performance, and cost implications.

 

For more information, visit: https://www.paconsulting.com/industries/transport/rethinking-feedstocks-for-saf-report