Sustainability in Aircraft MRO: Building a Greener Future
With the Maintenance, Repair, and Overhaul (MRO) sector’s critical importance growing every day due to fleet expansion and modernization—especially with the 2050 goal of achieving net-zero emissions—sustainability has become a mission statement. MRO operators are setting up their sustainable future, and many have been quick to adopt methods that reduce their environmental footprint. At the same time, they continue to ensure the safety and reliability of services, in line with customer expectations and regulatory standards.
Sustainable MRO practices include recycling and reusing aircraft parts with proper certification, supported by efficient logistics and inventory management. The latter has a major impact; according to Lufthansa Technik, the industry carries 30–40% excess inventory, resulting in parts being shelved and eventually becoming obsolete.
Regulatory mandates keep sustainability at the forefront, necessitating investments in green technologies and eco-friendly practices. These include using environmentally safe materials, recycling parts, reducing waste, and contributing to a circular economy.
For instance, Lufthansa Technik has been pioneering in recycling aircraft parts, thereby reducing waste and minimizing the need for new raw materials. This approach not only lessens environmental impact but also lowers operational costs.
MRO facilities can also achieve significant energy efficiency by introducing renewable energy into lighting and HVAC systems, potentially cutting costs by up to 20%. Delta TechOps, for example, has installed solar panels and energy-efficient systems across its facilities, resulting in measurable reductions in energy consumption and costs.
Digital tools and advanced analytics—including predictive maintenance, digital twins, and IoT—play crucial roles in monitoring and optimizing asset performance. These technologies cut down on waste and ensure the judicious use of resources.
Sustainable supply chain initiatives, such as setting stringent sustainability criteria for suppliers, ensure that every part of the supply chain contributes to overarching sustainability goals. Collaboration across the industry is also essential for fostering innovation and sharing best practices. One notable example is Airbus’s partnership with various MRO providers to develop solutions that reduce the carbon footprint of aviation fuels.
Industry Insights
According to a McKinsey study, digital transformation in MRO can deliver a 10–15% increase in productivity and a 5–10% reduction in maintenance costs. Advanced tools can address potential issues pre-emptively, reduce downtime, and minimize resource wastage.
Monica Badra, Founder of Aero NextGen, highlights a proactive approach:
“At Aero NextGen, we believe that sustainability is not just a compliance requirement but a strategic advantage. By enabling MRO aviation software to integrate sustainable practices into their operations, we not only reduce our environmental impact but also enhance efficiency and competitiveness.”
Manoj Singh, President of Global Aerospace at Ramco Systems, adds:
“The future of MRO aviation software lies in the seamless integration of digital technologies with sustainable practices. Our goal is to create a resilient and eco-friendly MRO ecosystem that can adapt to the changing needs of the aviation industry.”
Greener Practices for MROs
KPMG reports that both MRO and ground handling should achieve a 50% reduction in emissions intensity by 2050. Achieving this goal involves multiple factors—sustainable aviation fuels (SAF), the design of greener aircraft, electrification of ground vehicles, renewable energy use in MRO facilities, and streamlined processes.
Extending aircraft lifespans is one of the most basic yet effective sustainability measures. Regular maintenance, timely repairs, and proper upkeep ensure aircraft remain airworthy for longer, reducing the environmental impact of manufacturing new ones.
MRO activities that directly improve fuel efficiency—such as regular engine checks and component repairs—are vital. Effective scheduling further maximizes these benefits.
MROs are also adopting eco-friendly ground operations, including electric or hybrid service equipment, and reducing energy use in hangars and facilities.
The digitalization of maintenance operations cuts paper waste while improving speed and accuracy. Real-time job visibility and resource tracking allow for judicious allocation, while barcode scanning simplifies workflow management. Predictive analytics powered by real-time data helps forecast maintenance needs, prolong part lifespans, and optimize fuel consumption. Deloitte estimates that predictive approaches can reduce maintenance costs by 25% on average.
Disciplined Inventory Management
Enhanced inventory management reduces waste and excess by forecasting part demand, minimizing overstocking, and avoiding underutilization. This indirectly lowers emissions across the supply chain by improving logistical efficiency.
Cloud solutions make data and systems accessible remotely, reducing the carbon footprint associated with commuting and travel.
Contributing to a Circular Economy
A key aspect of sustainable MRO is the shift towards a circular economy, which emphasizes recycling, refurbishing, and reusing materials. Components such as fan blades, turbine parts, and landing gear can be overhauled multiple times, reducing the need for new parts. Practices like parts pooling and sharing enable faster turnaround and decrease demand for manufacturing new components.
MROs also manage hazardous waste from solvents and lubricants through automated chemical management systems and certified waste disposal services, thereby reducing soil and water contamination.
Being Energy Efficient
Energy consumption is a major contributor to emissions in MRO operations. Facilities are switching to renewable energy sources, such as solar and wind, cutting down on fossil fuel dependency. Smart lighting solutions and energy-efficient HVAC systems also play a role.
Research into the “Hangar of the Future” concept—led by institutions such as Cranfield University’s IVHM Centre—focuses on integrating robotics, AI, and advanced materials. Such innovations are expected to reduce downtime and costs while improving safety and environmental impact.
Smart Logistics and Carbon Reduction
MROs, reliant on global supply chains, can embrace smart logistics to reduce emissions. Optimizing routing, consolidating shipments, and working with local suppliers helps lower fuel consumption, emissions, and lead times.
By participating in circular economy initiatives, minimizing hazardous waste, improving energy efficiency, and optimizing logistics, MRO providers position themselves as leaders in sustainable aviation. The UN’s COP27 conference emphasized that sustainability must be integrated into every business strategy. For aerospace and defense, with their high-value assets, sustainability holds double importance.
Digitalization plays a large role here. A digital MRO platform can capture teardown and reassembly issues, provide feedback to engineering teams in real time, and drive continuous improvement.
Sustainability as a Core ESG Component
Sustainability forms one of the three pillars of ESG—environmental, social, and governance. For MRO companies, this translates to smarter use of resources, optimized supply chains, and efficient labor and energy management.
Digital technologies infused into MRO practices will remain central to achieving sustainability, with a focus on operational efficiencies and cost savings.
