As global air travel continues to rebound, airlines are increasingly holding onto older aircraft, investing billions in refurbishments to ensure passengers experience modern comfort. Delays in new aircraft deliveries due to supply chain disruptions have forced airlines to rethink their strategies, opting to upgrade aging fleets rather than retire them.

Massive Investments in Aircraft Refurbishments

Major carriers such as Emirates and Etihad have launched extensive refurbishment programs to modernize their aircraft interiors. Etihad has pledged $1 billion (€920 million) to upgrade its Boeing 777 and 787 fleets, while Emirates is investing a staggering $5 billion (€4.6 billion) to revamp its planes.

Finnair is also undergoing a major overhaul, refurbishing its long-haul Airbus A330 fleet and upgrading its regional Embraer E190s, some of which are nearly two decades old. The airline is modernizing the cabins with new slimline seats, fresh interior designs, and lightweight materials to enhance passenger comfort while improving fuel efficiency.

“We see this renewal as an important investment in travel comfort,” said Eeva Mattila, an engineer at Finnair Technical Operations. “Our aim is to provide a fresh and inviting travel environment for our customers.”

Supply Chain Delays Force Airlines to Adapt

Airlines’ reliance on older aircraft stems from significant delays in new aircraft production. Emirates, for instance, was expecting deliveries of Boeing’s 777X aircraft starting in 2020, but not a single jet has arrived. The airline has now expanded its refurbishment program to 220 planes.

“We have no choice,” Emirates CEO Sir Tim Clark stated at a tourism fair in Berlin. “This is the only way we can sustain and grow our network.”

Industry-wide delays have led to an increase in the global average aircraft age, now at a record 14.8 years—up from just over 13 years before the pandemic. While airlines emphasize that refurbished aircraft maintain high safety and comfort standards, aging fleets pose challenges for the industry’s sustainability goals.

Sustainability and Efficiency in Refurbishments

To offset the environmental impact of older aircraft, airlines are incorporating sustainable materials into their refurbishments. Finnair, for example, is using recycled leather instead of traditional cowhide, reducing carbon emissions by up to 85%. Similarly, lightweight seating options, such as Recaro seats, are being installed to lower fuel consumption and emissions.

KLM’s Boeing 737 refurbishments in 2021 resulted in a 20% reduction in seat weight, cutting carbon emissions by 184 tonnes per aircraft annually. Air France has taken similar steps, opting for ultra-lightweight, recycled components in its Embraer fleet.

Upcycling Old Aircraft Interiors

Rather than discarding outdated materials, airlines are finding innovative ways to repurpose old aircraft interiors. Emirates has turned discarded seat leather into luxury travel accessories, while Finnair has sold its used seats to budget carriers and developing nations.

For passengers, the focus remains on comfort and experience rather than aircraft age. With airlines investing heavily in modernizing older jets, travelers can expect a fresh and upgraded flying experience, even on planes that have been in service for decades.