Air India Embarks on $400 Million Overhaul of B787-8 Fleet, Expands Retrofit to Other Aircraft

Air India Embarks on $400 Million Overhaul of B787-8 Fleet, Expands Retrofit to Other Aircraft

New Delhi: Air India has kicked off a sweeping $400 million aircraft modernisation drive, aiming to upgrade both widebody and narrowbody fleets with state-of-the-art interiors and systems designed to raise passenger comfort and operational reliability.

The initiative began with the first of 26 Boeing 787-8 Dreamliners tail number VT-ANT arriving at Boeing’s California facility in July for a full interior makeover. A second aircraft will join in October, with both expected back in service by December 2025 sporting fresh cabins, advanced in-flight entertainment, and enhanced amenities.

By mid-2027, all 26 B787-8s will feature redesigned interiors across three cabins Business Class, Premium Economy, and Economy with new seats, upgraded galleys and lavatories, refreshed carpets and curtains, and improved cabin materials in line with Air India’s revamped brand standards.

Thirteen Boeing 777-300ERs will also undergo similar upgrades starting in early 2027, though supply chain issues have pushed the completion date to October 2028.

To further boost dependability, Air India has launched a Reliability Enhancement Programme for its 26 legacy B787-8s. This involves detailed reviews of maintenance and configuration records, followed by Boeing-recommended modifications to reduce operational disruptions. Seven of these Dreamliners will also undergo heavy D-check maintenance in California.

On the narrowbody front, Air India’s 27 legacy Airbus A320neo aircraft are being progressively refurbished under a programme launched in September 2024. The work, taking place at GMR’s Maintenance, Repair, and Overhaul (MRO) facility in Hyderabad, has been accelerated with the addition of a third production line.

So far, 15 A320neos have completed retrofits, with the 15th aircraft returning to service on August 9, 2025, and the 16th slated for August 11. The remaining 11 are expected to be completed by September 2025.

Air India says these upgrades are part of a broader transformation plan to deliver “world-class service and operational excellence” as it prepares for a new era of global competitiveness.


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