Following its return to Tata ownership in 2022, Air India embarked on an extensive fleet rebuilding process, focusing on revitalizing its decades-old aircraft. A major milestone was achieved with the return of VT-ALL, a Boeing 777-300ER, marking the completion of a comprehensive refurbishment program. The airline plans to retrofit the aircraft and others in its fleet starting in 2027, enhancing passenger amenities and updating the airline’s livery.
VT-ALL had been grounded since February 2020 due to technical issues and aging components. It was flown into the AIESL Nagpur Maintenance Repair Organization in May 2025, where it underwent an intensive restoration that included over 3,000 component replacements, 4,000 maintenance tasks, and complete systems overhaul. This process was carried out under strict regulatory oversight in cooperation with Boeing and India’s DGCA, with multiple checks ensuring safety and performance compliance.
Safety and Regulatory Highlights
The aircraft successfully completed test flights and received the Airworthiness Review Certificate, allowing it to resume operational status. Such comprehensive restoration reflects India’s growing capabilities in high-complexity aircraft maintenance and highlights Air India’s commitment to engineering excellence.
Safety Concerns at European Airports
Amid the fleet overhaul, concerns have arisen from the European Aviation Safety Agency (EASA), which reported safety lapses during inspections at European airports. The findings ratio on Air India aircraft was 1.96 in January but has since decreased to 1.76, yet safety experts note that a ratio below 1 is considered optimal. An official from Air India attributed the elevated ratio to aging fleet issues and supply chain delays, with EASA inspectors reviewing aspects such as emergency exits and operational documents to ensure compliance.
Overall, Air India’s fleet renewal efforts continue, supported by rigorous safety checks and international standards, safeguarding its expansion and reputation in global markets.
