As the sustainable aviation fuel (SAF) industry continues to scale, project viability depends on much more than promising chemistry. While new pathways and technologies continue to emerge, many projects struggle to bridge the gap between laboratory validation and reliable, large-scale operations—especially when multiple first-of-a-kind elements are integrated into a single facility.For <a href="https://www.vistaprojects.com/?utm_source=saf_magazine&amp;utm_medium=paid_article&amp;utm_campaign=industry_pub&amp;utm_content=march_feature&amp;utm_term=vistaprojects ">Vista Projects</a>, a Calgary, Alberta-based engineering and project delivery firm, that reality has defined its growing role in the SAF sector. “We’ve seen firsthand: Just because the chemistry works doesn’t mean the commercial project will work,” says Arman Hassan, a project manager at Vista Projects. “Scaling and integrating a process into a continuously operating commercial plant is a very steep climb.”Digital Execution to SAF Engineering&nbsp; Vista was initially brought into a SAF project to establish a digital project execution environment integrating engineering, construction and operations.That engagement quickly expanded. “What started as front-end engineering support and advisory services evolved into full detailed engineering, procurement support and owner’s engineering,” Hassan says. The project—an electro-SAF (eSAF) facility using a first-of-a-kind technology configuration—presented both technical and commercial challenges. Vista ultimately assumed most of the engineering scope after the previous contractor struggled to manage the project’s complexity. According to Hassan, success depended on ensuring all plant systems and interfaces could be delivered and run as one integrated facility.Vista has since expanded into a commercial-scale gas-to-liquids project using the Fischer-Tropsch pathway and expects to support multiple pathways as demand evolves, helping owners clear key project gates by bringing execution discipline, integration capability and delivery experience.Compounding Complexity&nbsp; Across pathways, Hassan says it’s often underestimated how quickly complexity compounds when new SAF technologies are integrated with utilities/offsites, hydrogen, storage and blending, and stringent fuel specifications—often simultaneously.&nbsp;Adding to that challenge are interface gaps between licensors, EPC firms and vendors. Scope splits that appear logical during development can create significant risk once projects enter detailed engineering. “Late design validation, late HAZOPs and late operational requirements are all symptoms of insufficient front-end discipline,” Hassan says. “So, it’s really important to pick the right partners and licensors.”Even when engineering is optimal, external constraints—permitting timelines, labor availability and construction constraints—can still derail schedules.Much More Than Drawings&nbsp; Vista views itself as a project developer’s engineering partner—an approach it believes is critical for SAF projects, especially those led by startups or new entrants. “A lot of projects fall apart when there isn’t a strong owner team managing interfaces, risk and decision-making,” Hassan says. “<a href="https://www.vistaprojects.com/consulting/owners-engineering-projects/?utm_source=saf_magazine&amp;utm_medium=paid_article&amp;utm_campaign=industry_pub&amp;utm_content=march_feature&amp;utm_term=ownersengineering ">Owner’s engineering</a> is about protecting the owner’s interests, not just delivering drawings.”That role includes overseeing licensors and EPC contractors, managing change, driving cost and schedule transparency, aligning stakeholders and ensuring technical decisions connect back to commercial reality. Vista also supports partner selection, providing an impartial view on licensors, EPCs, fabricators, constructors and key vendors grounded in execution track record.One of the most common pitfalls Vista sees is inadequate front-end definition, particularly when teams move quickly past feasibility. “Strong front-end definition—a clear design basis, realistic yields and structured cost estimates—is critical to avoid sticker shock as projects move forward,” Hassan says.Another risk area is scale-up strategy. Many SAF projects attempt to leap from lab proof-of-concept to commercial operation without sufficient intermediate validation, limiting opportunities to confirm performance and operability under pilot or demonstration conditions.Feedstock: A Core Design Basis&nbsp; As competition for SAF feedstocks intensifies, Vista urges developers to rethink how feedstock is treated during project development. “Feedstock is a core design basis that affects pretreatment, catalysts, corrosion, wastewater, reliability and overall economics. So, you have to design for it deliberately.”Seasonality, quality variation, supply-chain logistics and local constraints should be reflected in plant design from the outset, along with a realistic understanding of how impurities affect performance and maintenance. Hassan notes that downstream requirements can be overlooked early, including product specifications and certification expectations that influence design and operations.While many developers seek maximum feedstock flexibility, Vista cautions that flexibility comes at a cost. “You can design for a range within a targeted envelope, but you can’t design a plant to handle everything while meeting the project’s economic drivers,” Hassan says.De-Risking with the Right Partners&nbsp; As SAF development continues, Vista is strengthening its repeatable delivery playbook by incorporating lessons learned, standardized risk frameworks and improved execution strategies. The company also leans on modularization and digital execution expertise to reduce field costs, improve transparency and manage complexity—especially in high-cost jurisdictions where labor constraints can dominate project economics.“We’re applying what we’ve learned from projects over the years—we’re very strong around hydrocarbon processing and complex energy projects, including startup-led development—to help future developers de-risk their approach,” Hassan says.For companies entering the SAF space, Vista’s advice is straightforward. “Don’t shortcut feasibility,” Hassan adds. “Define your feedstock and offtake early, choose partners with execution experience, and design for real-world operating conditions—not lab science. It’s a technically exciting space with real potential, but you have to de-risk early with disciplined execution and the right partners.”<a href="www.vistaprojects.com">www.vistaprojects.com</a>&nbsp;&nbsp;

SPOTLIGHT | VISTA PROJECTS: De-Risking SAF with the Right Design

Upcoming Events

Carbon Capture & Storage Summit

International Fuel Ethanol Workshop & Expo

Sustainable Fuels Summit: SAF, Renewable Diesel and Biodiesel

North American SAF Conference & Expo

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Upcoming Events

Carbon Capture & Storage Summit

International Fuel Ethanol Workshop & Expo

Sustainable Fuels Summit: SAF, Renewable Diesel and Biodiesel

North American SAF Conference & Expo

SPOTLIGHT | VISTA PROJECTS: De-Risking SAF with the Right Design