Air India restores last of grounded fleet to operations

When Air India returned to the Tata Group in 2022, one of the airline’s biggest priorities was rebuilding its fleet and restoring world‑class operational capability. Among the inherited legacy fleet of 113 aircraft were 30 widebody and narrowbody aircraft that had remained long‑grounded and untouched for years. Post-privatisation, Air India committed significant resources to revive each of them. The airline said with the return of VT‑ALL, the last of the 30 grounded aircraft, a Boeing 777‑300ER, the final chapter of this massive revival effort is now complete. In the next phase, VT-ALL and the other B777 aircraft in the fleet will undergo a full retrofit, starting 2027. With the retrofit, the aircraft will offer the new Air India experience with new seats and modern amenities while sporting our new livery. VT‑ALL had been grounded since February 2020 due to multiple unserviceable systems and aging components. In April 2025, Air India initiated efforts to bring it back to full operational life to support long‑haul expansion. The aircraft entered the AIESL Nagpur MRO facility in May 2025, beginning an intensive, nose‑to‑tail restoration programme. The scale of the task was exceptional: 3,000+ new key components installed – an undertaking rarely seen outside of deep structural overhauls 4,000+ maintenance tasks completed, including 80 mandated modifications such as the complex Longeron Modification, a crucial structural reinforcement Replacement of major assemblies including engines, APU, inlet & fan cowls, and thrust reverser cowls A full systems rebuild – covering air-conditioning, landing gear, hydraulics, oxygen, avionics, and engine systems – essentially reconstructing the aircraft’s functional backbone Each part replacement, system restoration, and structural repair underwent stringent testing, documentation, and regulatory oversight by DGCA, with technical guidance from Boeing. Skilled engineering teams worked nearly round the clock to bring the aircraft back to life. The revival of VT‑ALL was driven by seamless coordination across Air India’s base maintenance, planning, technical services, procurement and supply chain, Project Management Office (PMO) powerplant, Continuing Airworthiness Management Organisation (CAMO), and quality assurance teams. Their combined effort ensured the aircraft was restored in record time and to the highest safety and performance standards. VT-ALL has met with all the regulatory safety compliances in its path of restoration, including successfully completing the ‘Test Flight’ of the aircraft. It has also been accorded the Airworthiness Review Certificate (ARC) – a mandatory certification of the safety parameters for an aircraft to commence regular operations. With VT‑ALL’s return, Air India has successfully revived every single one of the 30 previously grounded aircraft. These aircraft, now fully operational, stand as proof of India’s growing capabilities in high‑complexity aircraft maintenance and Air India’s unwavering commitment to engineering excellence. EASA raises concerns about Air India planes The European Aviation Safety Agency (EASA) has reportedly raised concerns about safety lapses on Air India flights following surprise inspections at European airports. EASA reported multiple issues after the ratio of findings per inspection on Air India aircraft reached 1.96 in January. This led EASA to inform India’s Directorate General of Civil Aviation (DGCA), which increased scrutiny of the airline’s operations. According to a report in The Economic Times, a ratio above 2 could affect Air India’s ability to operate in key European markets, with aircraft facing more inspections or operational bans. In response, DGCA took corrective measures to reduce the airline’s fault count and avoid restrictions. Since then, the finding ratio has decreased to 1.76 as of last week, according to a senior DGCA official. Airlines with strong safety records usually maintain a ratio below 1. A senior Air India official told the financial daily that the high number of findings is due to the airline’s ageing fleet. Delays in a $400 million refurbishment programme, started after the Tata Group took control, have been worsened by supply chain issues faced by global vendors. The official said that “European standards are very high” and that a broken seat or a worn-out emergency marking are also recorded by EASA inspectors as violations. EASA inspectors review about 54 safety parameters, including emergency exits, life jackets, crew licensing and operational documents to ensure compliance with international standards. For Editorial Inquiries Contact: Editor Matt Driskill at [email protected] For Advertising Inquiries Contact: Head of Sales Sally Passey at [email protected]