Dreamliner refresh: Air India begins $400m Boeing 787 upgrade
Air India has begun a refit programme of its Boeing 787-8s, launching the first stage of a $400 million cabin and systems upgrade aimed at improving passenger comfort and operational reliability.
The move comes in the wake of the deadly Ahmedabad crash earlier this year and following the merger with Vistara, which has added more Dreamliners to the fleet.
The retrofit programme has now started with aircraft VT-ANT, which was flown to Boeing’s facility in Victorville, California, in July.
A second airframe will follow in October, with both expected back in service before the end of the year.
Air India embarks on total Boeing 787 retrofit programme
Over the next two years, all 26 legacy 787-8s will be refitted with an entirely new three-class interior: Business Class, Premium Economy and Economy.
Each cabin will receive new seating, updated inflight entertainment, refreshed galleys, lavatories, soft furnishings and décor to match the airline’s redesign, which included a new livery and brand identity.
Reliability upgrades will run alongside the cabin work, including avionics improvements and heavy D-check maintenance on seven aircraft.
The project also extends to other widebody types. From early 2027, 13 Boeing 777-300ERs will undergo a similar transformation, although their completion date has shifted to late 2028 due to supply chain constraints. Once back in service, the aircraft will support Air India’s international flying programme.
Meanwhile, narrowbody refurbishment continues with Air India’s 27 older A320neos being upgraded with new interiors.
Some 16 have already been completed and reintroduced on domestic and short-haul international routes.
Integrating Vistara’s Dreamliners
The merger with Vistara, finalised in November 2024, has further reshaped Air India’s fleet.
Seven Boeing 787-9s from Vistara have now joined the roster, boosting long-haul capacity and enabling a more rapid expansion of the Dreamliner network.
These aircraft are being aligned with the same product and operational standards as the retrofitted 787-8s.
The retrofit programme starts amid intense scrutiny of Air India and its Dreamliners in the wake of the June crash.
The Ahmedabad crash
The incident on 12 June 2025 involved Flight AI 171, a 787-8 that came down just after departure from Ahmedabad, striking the BJ Medical College campus.
Only one person aboard survived, and 19 people on the ground were also killed.
Investigators say both engine fuel control switches were suddenly moved to “CUTOFF” during the climb, shutting off fuel to the engines and causing a total loss of thrust.
In the cockpit recording, one pilot questioned the other about the cut-off, receiving the reply that he had “not done so.”
Since then, Air India has stepped up safety checks on its Dreamliner fleet and sought operational guidance from Singapore Airlines to align with international best practice.
Alongside the hardware changes, Air India has altered HR policies to retain experienced employees within its workforce.
Pilot retirement changes
The mandatory retirement age for pilots has been increased from 58 to 65, and for other staff from 58 to 60, helping achieve operational continuity during the fleet’s transformation.
This adjustment aligns Air India with the Directorate General of Civil Aviation (DGCA) rules, which cap the retirement age for commercial pilots on scheduled services at 65.
While carriers can opt to set an earlier cut-off, they cannot extend it beyond 65 unless specifically authorised by the regulator.
