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The entire retrofit exercise, including narrow and widebody aircraft, is being conducted under a $400-million programme for a phased revamp of Air India’s legacy fleet
Tata Group-promoted Air India will be sending first of its legacy widebody aircraft to the US for retrofit later in April, sources told businessline.
The entire fleet of legacy widebody aircraft comprising 27 B787s and 13 B777s is estimated to undergo retrofit in just over two years, a timeframe contingent on a constant and steady supply of components, sources said.
“The key project will take enormous effort and detailed planning, keeping the supply chain issue in mind,” sources told businessline.
“Once completed over a period of next two years, this retrofit will enhance the long-haul service standards for Air India’s passengers.”
According to sources, the exercise will commence in late April, starting with the first of the 27 Boeing 787-8 legacy aircraft inherited during the takeover by the Tatas.
“The first of 27 legacy Boeing B787 fleet, by which the seat vendors have been less impacted as compared to the B777s, will depart to Victorville, California, later this month where it will commence a full retrofit of new seats, inflight entertainment systems and other interior fittings, as well as receive Air India’s new livery,” sources said.
“Following its certification and return to service in September, the remainder of the fleet will undergo the same upgradation process, which is expected to be completed during 2027.”
The expansive overhaul, sources said, will enhance quality of service and extend the life of the aircraft.
“Each B787-8 aircraft is estimated to take 40 to 50 days of thorough overhaul,” sources cited.
$400 m programme
The entire retrofit exercise, of narrow and widebody aircraft, is being conducted under a $400-million programme for a phased revamp of Air India’s legacy fleet.
Besides, the airline has started the retrofit of its narrowbody A320 aircraft. The first two of these 27 narrowbody legacy Airbus A320neo aircraft have joined the fleet in March, operating in the domestic as well as short-haul international destinations.
As per sources, by the end of 2025, an additional 38 legacy narrowbody aircraft will be upgraded. Along with the 14 more new refitted narrowbody aircraft that are already operating in the domestic network and the new aircraft acquired from Vistara, Air India full-service fleet of over 120 narrowbody aircraft will have been upgraded to new standard.
Furthermore, two more retrofitted legacy A320neo aircraft will commence operations shortly.
All the 27 narrowbody A320neo aircraft that were inherited at the time of takeover will undergo complete retrofit to the new Air India standards by the third quarter of 2025.
Notably, the two already retrofitted aircraft received new seats, carpets, and curtains along with a fresh coat of paint and new livery.
Air India intends to install over 3,500 brand-new economy class seats, along with more than 600 premium economy seats and 200 business class seats for the narrowbody retrofit.
Additionally, the Tata Group-backed airline intends to press a “refreshed” widebody B777 into service in April.
The airline had initiated a ‘heavy refresh’ programme for its fleet of legacy Boeing 777 aircraft last month to provide an upgraded ultra-long-haul flying experience for its passengers.
Cabin experience
Sources said that the programme will enhance the cabin experience of the airline’s 13 legacy Boeing 777s. However, Air India’s 11 leased Boeing 777s are not a part of this exercise.
businessline was the first to report that Air India planned a gradual “hard or heavy” refresh programme for its fleet of old, legacy B777 aircraft to ensure its passengers on the ultra-long-haul flights have an elevated experience in the cabin till the time the actual retrofit commences for the B777s.
The refresh programme is expected to make a “significant” impact on the airline’s ultra-long-haul passenger experience, as the B777s serve Air India’s most high-profile international routes.
“The first of 13 legacy Boeing B777 aircraft has just completed an interim “heavy refresh” that involved replacing interior panels, lavatories, seat upholstery, carpets, and curtains, with the remainder to follow in the coming months,” sources said.
Protracted delays
“The decision to undertake this interim heavy refresh ahead of full retrofit was made due to protracted delays in the delivery of seats from the contracted vendors, arising from industry-wide supply chain constraints.”
These ‘refreshed’ aircraft, sources added, will return to the hangar as new seats and inflight entertainment systems become available for installation by late 2026-27.
Published on April 3, 2025
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