PSI and Metafuels Inaugurate 'Aerobrew' Demonstration Plant for Sustainable Aviation Fuel
Why It MattersThe project signals continued momentum behind synthetic, power-to-liquid SAF pathways as an alternative to biogenic feedstocks for decarbonising aviation fuel supply.
A demonstration plant using the novel 'aerobrew' technology to produce sustainable aviation fuel (SAF) was officially inaugurated on 20 August 2026 at the Paul Scherrer Institute (PSI) campus in Switzerland, a joint project of PSI and Zurich-based startup Metafuels. More than 150 guests attended, including Aargau cantonal government member Dieter Egli, Federal Office of Civil Aviation director Francine Zimmermann, and SWISS CEO Jens Fehlinger.
The plant is designed to produce 50 litres of SAF per day and is described as the world's first facility integrating all production steps for synthesising aviation fuel from methanol under one roof. The patented 'aerobrew' process converts water, renewable electricity, and carbon dioxide into synthetic kerosene: hydrogen is produced from water using sustainable electricity, combined with CO2 to generate green methanol, from which the final fuel is synthesised. Carbon dioxide feedstock can come from biogenic sources such as wood or plant waste in the near term, and eventually from direct air capture.
PSI Director Christian Rüegg called the inauguration "an important milestone on the path to more sustainable aviation," while PSI researcher and project lead Marco Ranocchiari said the plant allows the technology to be tested under real-world conditions ahead of industrial scale-up. Metafuels co-founder and CEO Saurabh Kapoor said the product is designed for integration into existing airport infrastructure and conventional jet engines, with the company planning to bring its first commercial 'aerobrew' SAF production facility into operation starting in 2030.
