Airline aims to complete upgrades for all 26 legacy Dreamliners by the end of 2027
Air India is accelerating the modernization of its Boeing 787-8 Dreamliner fleet by expanding its global aircraft retrofit network, adding Boeing’s Maintenance, Repair and Overhaul (MRO) facility in Shanghai, China, to support ongoing refurbishment work alongside an existing facility in the United States.
The move is expected to speed up the airline’s fleet transformation program, which targets the completion of upgrades for all 26 legacy Boeing 787-8 aircraft by the end of 2027. The expanded maintenance capacity comes as the Tata Group-owned carrier continues to invest in improving its long-haul passenger experience and standardizing cabin products across its international fleet.
Air India Adds Second Overseas Retrofit Line
Until now, Air India had relied on Boeing’s retrofit facility in the United States for extensive cabin refurbishment and maintenance work on its Boeing 787-8 aircraft. The addition of the Shanghai MRO facility allows the airline to carry out upgrades at two international locations simultaneously, helping reduce maintenance bottlenecks and improve turnaround times.
The first aircraft assigned to the Shanghai facility is Boeing 787-8 registered VT-ANZ, marking the start of retrofit operations in China. Another aircraft, registered VT-ANR, is scheduled to undergo refurbishment at Boeing’s facility in Victorville, California.
According to industry sources, Air India is also evaluating additional international retrofit locations to further increase capacity. Any future expansion will depend on maintenance slot availability and operational capabilities at Boeing’s partner facilities.
The dual-facility approach is expected to enable multiple aircraft to be upgraded at the same time, significantly increasing the pace of the refurbishment program.
Fleet Modernization Remains a Key Priority
The retrofit initiative forms part of Air India’s broader fleet transformation strategy following its acquisition by the Tata Group. The airline has been investing in upgrading both its narrowbody and widebody aircraft as it seeks to improve product consistency and compete more effectively in international markets.
Comprehensive Cabin Improvements
Each Boeing 787-8 undergoing refurbishment receives a comprehensive interior and exterior overhaul designed to align the aircraft with Air India’s latest product standards.
The upgrades include:
- A refreshed passenger cabin experience
- Air India’s latest branding and exterior livery
Three Boeing 787-8 aircraft have already completed the retrofit program and have returned to commercial service featuring the airline’s updated cabin products.
The modernization effort is intended to deliver a more consistent onboard experience across Air India’s long-haul Dreamliner fleet while supporting the airline’s wider transformation plans.
Maintenance Requirements Can Extend Downtime
Heavy Maintenance Combined With Cabin Upgrades
Although a standard Boeing 787-8 retrofit typically takes around 30 days, project timelines can vary depending on scheduled maintenance requirements.
For example, the recently refurbished aircraft VT-NAC remained out of service for more than 90 days after Air India combined heavy maintenance inspections with cabin refurbishment and repainting work during a single maintenance visit.
By completing structural inspections, maintenance tasks, repainting, and cabin upgrades at the same time, the airline aims to reduce future operational downtime once the aircraft returns to commercial service.
This integrated maintenance approach allows Air India to maximize aircraft availability over the longer term while minimizing the need for separate maintenance events.
Airline Targets Faster Completion Through Dual-Facility Operations
With refurbishment work now underway in both Shanghai and the United States, Air India expects the pace of the program to increase significantly over the coming months.
The airline plans to have approximately 10 to 12 Boeing 787-8 aircraft fully upgraded by April 2027. Operating multiple retrofit lines enables several aircraft to undergo modernization simultaneously, improving efficiency compared with relying on a single maintenance location.
Air India is also using a temporary reduction in parts of its international network to send additional aircraft for refurbishment without causing major disruptions to scheduled passenger services.
End-of-2027 Goal Remains Unchanged
The airline continues to target the completion of retrofit work on all 26 legacy Boeing 787-8 Dreamliners by the end of 2027.
Once completed, the program will provide a standardized onboard product across Air India’s Boeing 787-8 fleet, supporting the carrier’s long-term strategy of enhancing customer experience while modernizing one of its most important long-haul aircraft types.
The expansion of retrofit operations into Shanghai represents another step in Air India’s fleet renewal efforts as the airline works to accelerate aircraft upgrades and strengthen its position in the international aviation market.
