Pegasus Airlines open $40m in-house MRO facility

Pegasus Airlines open $40m in-house MRO facility

Turkish low-cost carrier Pegasus Airlines have significantly boosted their in-house MRO capabilities with a new US$40 million facility. Situated at Istanbul Sabiha Gökçen Airport, the facility consists of three new hangars, two for maintenance and one for paint. These provide space for simultaneous line and base maintenance for up to five narrowbodies.

By the end of 2026, another hangar will be constructed, enabling base maintenance for a further five aircraft. Güliz Öztürk, chief executive of Pegasus Airlines, said:

Every investment we make in technical infrastructure takes our operational strength one step further. Our aircraft maintenance centre investment at Istanbul Sabiha Gökçen Airport is a strategic milestone in Pegasus’ sustainable growth journey. Our new hangars will not only enable us to manage the maintenance needs of our growing fleet more effectively, but also accelerate our transformation focused on digitalisation and efficiency. By managing our aircraft maintenance processes more quickly and in a more optimised way, we aim to provide our guests with an ever more seamless travel experience.

The facility will support a range of technical processes, from avionics modification to aircraft painting and engine changing. Digitisation has been a key consideration in the construction, with the facility boasting a digital warehouse and tool management system, as well as AI-enhanced occupational health solutions.

Together, the hangars will create 200 jobs. While currently only caring for Pegasus aircraft, in future the airline said they would be open to third-party work as well.

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Saudia select Veryon Defect Analysis for prescriptive maintenance

Saudia select Veryon Defect Analysis for prescriptive maintenance

Saudia have selected aviation software and information services provider Veryon to support corrective action across their fleet.

Using AI and natural language processing, Veryon Defect Analysis can group related defect reports to highlight recurring maintenance problems and support proactive decision-making. As Saudi Arabia’s national carrier, Saudia has undergone significant expansion in recent years, aviation being a core component of the Kingdom’s Vision 2030 economic development strategy. Veryon’s solution will support its fleet of 160 aircraft, enabling continuous data analysis across the airline’s multiple business units.

Bethany Little, Chief Executive Officer at Veryon, said:

When an airline is scaling at the pace Saudia is, prescriptive health technology is a must-have and can dramatically improve reliability and an operation’s bottom line. Serving over 25% of the worldwide commercial fleet, Defect Analysis is the market-leading provider of prescriptive health maintenance solutions in the aviation technology market.

Veryon’s existing partners in the aviation industry include Airbus, Honeywell, and Lockheed Martin. The supply chain backlog shows no signs of clearing anytime soon, accelerating the adoption of prescriptive and predictive analytics. Having real-time data on hand can ensure airlines get the most out of ageing fleets. However, prioritising investment in these tools isn’t always easy, and must be matched by parallel investments in upskilling the digital skills of the workforce.

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Ryanair cuts deal with CFM to bring engine maintenance in-house

Ryanair cuts deal with CFM to bring engine maintenance in-house

Irish low-cost carrier (LCC) Ryanair have signed a 15-year services agreement with engine manufacturer CFM to bring maintenance capabilities in-house.

The terms of the deal will see the airline buy US$1 billion in spare parts annually from CFM, a joint venture between Safran and GE Aerospace. Ultimately, by 2029 Ryanair plan to open two engine maintenance shops that will be responsible for maintaining their 2,000 CFM engines.

Ryanair Group CEO Michael O’Leary explained that the move will reduce costs and expedite maintenance timelines. Currently, the LCC outsources its maintenance to CFM, which leaves Ryanair vulnerable to extensive supply chain backlogs and disruption. The ability to control their own turnaround times would be a ‘huge benefit, O’Leary explained. He said:

[This] is the way we will be able to limit cost inflation. There is no doubt there is going to be significant cost inflation on new aircraft, engines and engine repair for the next decade, until the supply chains begin to smooth out.

H Lawrence Culp, junior chairman and CEO of GE Aerospace, added:

We value the opportunity to work with them on solutions to increase capacity and reduce turnaround time. This MoU demonstrates our commitment to an open MRO ecosystem that supports growing demand while reducing cost of ownership,

Other airlines in Europe do their own engine maintenance, including Air France and Lufthansa. However, Ryanair’s move is a significant departure from the typical budget airline model, where maintenance is outsourced.

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Virgin Australia begins predictive maintenance with Embraer’s AHEAD

Virgin Australia begins predictive maintenance with Embraer’s AHEAD

Under a long-term agreement, Embraer will equip Virgin Australia’s fleet of E2s with its AHEAD (Aircraft Health Analysis and Diagnosis) system. AHEAD is designed to help airlines begin a predictive maintenance programme, providing critical information for identifying problem areas before they escalate.

Collecting data inflight and on-the-ground, AHEAD facilitates real-time monitoring of essential aircraft structures. This includes APUs, avionics, flight controls, and hydraulics. Improved sustainable performance is another advantage, as AHEAD limits avoidable fuel burn due to maintenance issues. Overall, the predictive maintenance software can reduce downtime and optimise fleet availability.

Virgin Australia Regional Airlines Executive General Manager, Nathan Miller said:

Our E2 jets are a game-changer, delivering a more reliable, efficient and comfortable experience for our customers. The AHEAD tool will help us stay in front of maintenance issues, ensuring we are getting the very best out of our new aircraft and helping us strengthen operational performance across our network.

Virgin Australia already run two E2 jets and have placed firm orders for eight more. Carlos Naufel, President and CEO, Embraer Services & Support, added:

This agreement with Virgin Australia underscores Embraer’s commitment to driving digital innovation in aviation. By integrating the AHEAD platform into the E2 fleet, we are enabling predictive maintenance that reduces unscheduled downtime, optimizes operational efficiency, and lowers maintenance costs. These capabilities help Virgin Australia maximize fleet availability and improve overall operational performance.

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Airbus predict services demand in APAC will reach $138.7bn

Airbus predict services demand in APAC will reach $138.7bn

Airbus’s latest Global Services Forecast (GSF) for the Asia-Pacific region predicts that services demand in the region will reach US$138.7 billion by 2044.

With a compound annual growth rate (CAGR) of 5.2%, APAC is set to be the most dynamic aviation services market in the world. 19,560 new passenger aircraft will be required to meet travel demand, Airbus believe, as passenger traffic looks set to grow at 4.4% annually.

The GSF divides the services market in APAC into seven key sectors:

  • Off-wing maintenance, worth US$100 billion in 2044, driven by expanding (and ageing) fleets. Supply chain challenges and labour shortages pose significant challenges to this segment.
  • On-wing maintenance, worth US$14 billion in 2044 as key MRO infrastructure develops and expands in fast-growing markets like India, Indonesia, and Malaysia.
  • Modifications and upgrades, worth US$6.2 billion in 20444. Airbus say cabin modernisation is being undertaken more regularly as airlines try and offer more premium products and the latest inflight connectivity (IFC) solutions in line with changing customer demand.
  • Digital and connectivity, worth US$11.2 billion in 2044, driven by widespread adoption of AI and data analytics for predictive maintenance, improved flight ops, and labour shortage mitigation.
  • Training, worth US$7.7 billion in 2044. Airbus predict that 1.06 million new aviation professionals will be required by 2044, including 282,000 pilots, 302,000 technicians and 473,000 cabin crew.
  • Maintenance operations support, worth US$46.4 billion by 2044, and a key enabler for operators and MROS.
  • Ground operations, worth US$31 billion by 2044 and undergoing complex restructuring as the sector incorporates automation and digital tools for improved performance.

Airbus conclude their notes on APAC by explaining:

As the aviation ecosystem continues to evolve, growth in services demand is increasingly concentrated in Asia-Pacific. Although mature markets will continue to provide scale, Asia-Pacific, driven by South Asia and China, will define the next phase of global aviation services growth, reshaping capacity, capabilities and investment priorities worldwide.

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Thai Airways advances plans for new MRO hub in Utapao

Thai Airways advances plans for new MRO hub in Utapao

Thai Airways are awaiting approval from the board of directors to construct a US$418 million MRO hub at Utapao in Southeast Thailand.

Work on the so-called ‘smart hangar’ would begin in 2027, with 2030 set as a targeted opening date. The proposed site lies beside U-Tapao Rayong–Pattaya International Airport’s second runway, which is currently under construction. Thai Airways will pay the government, who owe the site, through a revenue-sharing model set out over decades.

The new hangar would fill a critical gap in the Thai MRO market. At present, carriers in the country send most of their aircraft abroad for repairs and maintenance, driving up costs and increasing turnaround time. Thai Airways are currently undertaking a growth transformation strategy that will see their fleet expand to 150 aircraft as it targets US$12 billion in revenue by 2033.

As the aviation industry has taken off across Southeast Asia, MRO has become an increasingly pressing issue. Recent years have seen new facilities emerge in Bali, Indonesia, as well as in Kuala Lumpur and Singapore.

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