
The cost of fueling a 737 depends on several factors, including the aircraft's size and efficiency, sector length, taxi time, cargo weight, weather conditions, and jet stream direction. Fuel prices are also subject to market fluctuations influenced by global politics and supply dynamics. While it is challenging to determine the exact fuel cost per aircraft per flight, estimates indicate that the full cost of operating a 737-800 for an hour is approximately $5,500, with fuel constituting a significant portion of the total expenses.
| Characteristics | Values |
|---|---|
| Cost of fuelling a 737-800 for an hour | $3,800 |
| Full cost per hour of a 737-800 | $5,500 |
| Average fuel price for a flight between certain airports (as of 2019) | N/A |
| Fuel efficiency | Depends on the size and efficiency of the aircraft, sector length, taxi time, cargo weight, weather, jet stream direction, etc. |
| Fuel costs for airlines | 20-40% of expenditure |
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What You'll Learn

Fuel costs vary due to global politics and market fluctuations
Fuel is a major expense for airlines, accounting for 20-40% of their total expenditure. The cost of fuelling a 737 will depend on various factors, including aircraft size and efficiency, sector length, taxi time, cargo weight, weather, and jet stream direction. For example, a Boeing 747 uses approximately 1 gallon (about 4 litres) of fuel every second, resulting in 36,000 gallons (150,000 litres) of fuel burned over a 10-hour flight.
The volatility of the fuel market poses a challenge for airlines in managing their fuel costs. Fuel prices are influenced by global politics and market fluctuations, making it difficult for airlines to predict and control their fuel expenses. Taxes, fuel mandates, and the limited number of suppliers in the aviation industry further contribute to the variability in fuel costs.
To optimise fuel efficiency, airlines employ different strategies for fuelling their aircraft. Some airlines opt for refuelling only on the return journey, while others may carry enough fuel for a round trip or 1.5 trips. However, refuelling on the return journey can delay turnarounds, especially for a full tank top-up. Additionally, filling aircraft tanks to maximum capacity is generally inefficient due to the increased fuel consumption and decreased efficiency associated with heavier aircraft.
The variability in fuel costs across different airports also influences airlines' fuelling strategies. On shorter flights, it is common for airlines to carry enough fuel for the return trip, as fuel may be cheaper at their home airport compared to the destination. These factors collectively contribute to the dynamic nature of fuel costs, requiring airlines to adapt their strategies and manage the financial implications of fuel price fluctuations.
While it is challenging to calculate the exact fuel cost per aircraft due to constant market changes, understanding these factors is crucial for airlines to optimise their operations and manage the impact of fuel prices on their overall expenditure.
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Aircraft type, sector length, and weather affect fuel usage
The cost of fuelling a 737 depends on several factors, including the aircraft type, sector length, and weather conditions.
Aircraft type plays a significant role in fuel usage. Different aircraft have varying fuel efficiencies due to factors such as engine type, weight, aerodynamics, and technology used. For example, turboprop airliners are generally more fuel-efficient than jet airliners due to their propellers. Additionally, older aircraft like the 1950s piston airliners are less fuel-efficient than modern jet airliners. The weight of the aircraft is also crucial; a lighter airframe generates lower drag, resulting in better fuel efficiency.
Sector length, or the distance travelled, also affects fuel usage. Longer sectors require more fuel to complete the journey. However, the efficiency of the aircraft at different altitudes and speeds can impact fuel usage. Flying at optimum altitudes and speeds can improve fuel economy. Additionally, direct routing can reduce the distance travelled, lowering fuel consumption.
Weather conditions, such as air temperature, can influence fuel usage. Cold temperatures, with denser air, increase thrust and allow aircraft to generate more lift. This can lead to improved fuel efficiency and shorter take-off distances. In contrast, hot temperatures result in less dense air, reducing thrust and lift. As a result, aircraft may require longer runways or need to reduce their mass, impacting fuel efficiency.
While I cannot provide a specific cost for fuelling a 737 as it depends on various factors and fuel prices, which vary over time, I can offer some context. In 2017, the estimated full cost per hour of operating a 737-800, including fuel, plane, maintenance, and staff, was about $5500 per hour. This provides a starting point for understanding the potential costs involved in fuelling and operating this type of aircraft.
Additionally, some strategies can help reduce fuel usage. For example, Airbus suggests that aircraft flying in formation, similar to migrating birds, can save 5-10% of fuel due to wake updraft. This strategy has been tested and could be implemented in commercial operations in the future.
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Airlines have different refuelling strategies
Fuel is a major expense for airlines, accounting for 20-40% of their total expenditure. The cost of fuel is subject to market fluctuations influenced by global politics, and the price varies depending on the region. Aircraft type, sector length, taxi time, cargo weight, weather, and jet stream direction are some of the factors that determine how much fuel a flight consumes.
Additionally, aircraft rarely fill their tanks to the maximum unless they are stretched to a range limit. A heavier aircraft burns more fuel, reducing efficiency and increasing costs. Some airlines will fill their tanks with enough fuel for 1.5 trips, ensuring they have sufficient fuel for the return journey while minimising the weight during the initial departure.
The cost of refuelling equipment and specialised aircraft handling requirements have limited in-flight refuelling to military operations. Aerial refuelling, also known as air-to-air refuelling, has been utilised in large-scale military operations since the Vietnam War. This strategy allows for force multiplication, enabling fighters to loiter longer over targets and carry increased weapon loads.
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$19.49

Fuel taxes and mandates impact prices
Fuel is a major expense for airlines, accounting for 20-40% of their total expenditure. The price of aviation fuel is subject to market fluctuations and is influenced by global politics, making it volatile. Airlines have little control over this cost and it is the most susceptible to market fluctuations.
Various factors impact the amount of fuel used by a 737 or any other aircraft. These include the size and efficiency of the aircraft, sector length, taxi time, cargo weight, weather, and jet stream direction. Aircraft do not usually fill their tanks to maximum capacity unless they are stretched to a range limit. This is because a heavier aircraft will burn more fuel, reducing efficiency and increasing costs.
Taxes and mandates on fuel also impact prices. Airlines and their customers pay various special taxes and fees to different authorities. These include taxes and fees for homeland security, environmental protection, agriculture inspection, infrastructure enhancement, airport operations and maintenance, and agency financing. Taxes on aviation fuel (jet fuel or kerosene) are levied in some countries, and there have been calls for an EU-wide tax on aviation to charge the industry for its emissions and pollution. In 2019, several European countries proposed uniform air passenger taxes and kerosene taxes. Some countries, such as Switzerland, have also considered environmental levies on airline tickets.
Fuel price increases have had a significant impact on the aviation industry. Commercial airlines have taken steps to mitigate the financial impact, such as restraining the growth of domestic seat capacity, improving fuel efficiency, and reducing weight on board. Airlines have also used fuel hedging to manage future price uncertainty. Fuel price increases have contributed to a decline in general aviation activity, including a reduction in the hours flown by general aviation aircraft.
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Calculating exact fuel costs per aircraft is challenging
Calculating the exact fuel cost for a specific aircraft type, such as the Boeing 737, is a challenging task due to various factors that influence fuel consumption and costs. Firstly, aircraft types differ in their fuel efficiency and size, which means that a Boeing 737 will consume a different amount of fuel compared to other aircraft models. The efficiency of an aircraft is also affected by its weight, with heavier aircraft burning more fuel. Therefore, factors such as cargo weight and passenger numbers can influence fuel consumption.
Sector length, or the distance of the flight, is another critical factor in determining fuel costs. Longer flights will naturally require more fuel, and the direction of the jet stream can also impact fuel efficiency. Weather conditions can play a role as well, affecting both the amount of fuel required and the efficiency of the aircraft's performance.
The decision of how much fuel to load is also a strategic choice for airlines. While aircraft can be filled to their maximum capacity, it is often inefficient from an engineering perspective as a heavier plane burns more fuel. Therefore, airlines may opt to fill the tanks for a round trip or just the outbound journey, and this decision can impact the overall fuel cost per aircraft.
Fuel prices themselves are subject to constant fluctuations due to market forces, global politics, and fuel mandates. These prices can vary across regions, and the limited choice of fuel suppliers for airlines compared to the numerous gas stations available to consumers further complicates the calculation of exact fuel costs.
Considering all these factors, it becomes evident that determining the precise fuel cost for a Boeing 737, or any other specific aircraft type, is a complex task with numerous variables at play. While estimates can be made, the dynamic nature of the aviation industry and its fuel requirements make it challenging to arrive at an exact figure.
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Frequently asked questions
The cost of fueling an aircraft depends on various factors, including the type of aircraft, sector length, weather conditions, and more. While an exact number is challenging to determine due to fluctuating fuel prices and varying fuel consumption rates, estimates place the hourly cost of operating a 737-800 at about $5,500, with fuel constituting a significant portion of this expense.
Several factors come into play when determining the fuel cost for a 737 flight. These include the price of fuel, which is subject to global market fluctuations and regional variations, as well as the amount of fuel required, which is influenced by factors such as aircraft size and efficiency, sector length, taxi time, cargo weight, and weather conditions.
The fuel efficiency of a 737 can be compared to other aircraft like the Boeing 747 and Airbus A380. While the 737's fuel consumption and efficiency figures are not directly available, it is known that a Boeing 747 burns approximately one gallon of fuel per second during a 10-hour flight, totaling about 36,000 gallons. In contrast, the Airbus A380 burns around 4,600 gallons of fuel per hour.











































