MRO & Manufacturing
EME Aero Expands GTF Engine Maintenance Capacity in Poland
EME Aero’s $37M Poland facility increases GTF engine servicing to 500+ units annually, integrating AI analytics and sustainable tech for aviation’s future.
The aviation industry is undergoing a significant transformation, driven by technological innovation, sustainability goals, and surging demand for next-generation aircraft engines. At the heart of this evolution lies the geared turbofan (GTF) engine, developed by Pratt & Whitney, known for its fuel efficiency and environmental performance. As the global fleet of GTF-powered aircraft expands, the need for efficient and scalable maintenance, repair, and overhaul (MRO) solutions becomes increasingly critical.
EME Aero, a 50/50 joint venture between Lufthansa Technik and MTU Aero Engines, has emerged as a key player in this space. With the inauguration of its second test cell in Jasionka, Poland, on June 30, 2025, EME Aero has significantly enhanced its capabilities. This $37 million investment not only increases the facility’s annual engine servicing capacity to over 500 units by 2028 but also positions the site as one of the most advanced GTF MRO centers globally.
This article explores the technical, economic, and strategic implications of EME Aero’s expansion, providing a comprehensive look at how this development fits into the broader context of aviation maintenance and sustainability.
Constructed in just 600 days, 30% faster than industry norms, EME Aero’s second test cell is a testament to engineering efficiency. Designed to handle all three GTF engine types (PW1100G-JM, PW1500G, and PW1900G), the facility incorporates cutting-edge technology such as high-frequency vibration sensors, AI-driven performance analytics, and automated fuel flow calibration systems. These features enhance diagnostic precision and reduce testing cycles by up to 15 hours per engine.
The test cell also incorporates robust environmental controls. Acoustic dampening systems reduce noise emissions by 40 decibels, while real-time emissions monitoring ensures compliance with stringent EU environmental regulations. These advancements reflect a broader industry trend toward greener, more sustainable aviation infrastructure.
Notably, the facility’s modular design allows for future upgrades, including compatibility testing for hybrid-electric propulsion systems and composite fan blades, essential for supporting the upcoming GTF Advantage engine, set to enter service in 2026.
“This expansion isn’t just about capacity, it’s about future-proofing the GTF ecosystem,”, Michael Schreyögg, Chief Program Officer, MTU Aero Engines.
EME Aero’s growth has significant economic implications, both locally and globally. The facility currently employs nearly 1,200 specialists and plans to expand to over 1,400 by 2028. This workforce development is supported by partnerships with local institutions like Rzeszów University, which recently launched a dedicated GTF maintenance curriculum.
Regional supply chain engagement has also surged, with a 70% increase in local procurement since 2023. Companies such as PZL Mielec now supply turbine components, creating a cascading economic effect throughout Poland’s “Aviation Valley.” MTU estimates that each engine serviced at EME Aero generates approximately $220,000 in local economic value, encompassing logistics, hospitality, and ancillary services. To meet future demand, EME Aero is investing in AI-assisted training simulators that reduce technician skill acquisition time by 30%, and expanding apprenticeship programs to ensure a steady pipeline of skilled labor amid a tight labor market.
The surge in GTF engine orders, nearly 1,100 in 2025 alone, underscores the technology’s market traction. Pratt & Whitney’s GTF family now accounts for approximately 29% of the narrowbody engine market, with more than 12,000 orders and commitments from over 90 airlines worldwide. This momentum is driven by the engine’s 20% fuel efficiency improvement and 75% noise reduction compared to previous-generation engines.
Airlines like Frontier, ANA, and Wizz Air have expanded their GTF fleets, citing not only performance benefits but also alignment with sustainability initiatives. Frontier Airlines, for instance, anticipates saving $1.2 million annually per aircraft in fuel costs, reinforcing its “America’s Greenest Airline” branding.
Looking ahead, the GTF Advantage engine promises even greater efficiency, 5% more fuel savings, 12% longer time-on-wing, and 15% higher takeoff thrust. These enhancements are expected to further solidify the GTF’s competitive position against rivals like CFM’s LEAP engine, which currently holds a 54% market share.
Geopolitical developments have also influenced MRO dynamics. Sanctions against Russia have redirected over 300 GTF engine orders to European and Asian carriers, increasing demand for localized maintenance capabilities. Additionally, Airbus’s 11% production increase for A320neos in 2025 has created immediate MRO demand across Europe.
Regulatory shifts, such as the EU’s “Fit for 55” initiative mandating 10% sustainable aviation fuel (SAF) usage by 2030, further amplify the importance of fuel-efficient engines like the GTF. MRO facilities that support these engines play a critical role in helping airlines meet environmental compliance requirements.
EME Aero’s strategic location in Central Europe allows it to serve a majority of European-based GTF engines within a 1,000 km radius, reducing logistical complexity and turnaround times. This geographic advantage enhances its role within Pratt & Whitney’s European MRO network, alongside MTU’s Hanover site and Lufthansa Technik’s Hamburg center.
EME Aero’s $37 million investment in its second test cell is more than an infrastructure upgrade, it is a strategic move that addresses current and future demands in the aviation industry. By boosting annual capacity to over 500 engines by 2028, the facility ensures it can support the growing GTF fleet, which is projected to log over 250 million flight hours by the mid-2030s. Beyond capacity, EME Aero is setting new benchmarks in technical innovation, environmental responsibility, and workforce development. Its expansion strengthens Poland’s position in the global aerospace ecosystem and demonstrates how regional hubs can play a pivotal role in supporting next-generation aviation technologies. As airlines increasingly consider MRO support in their fleet decisions, EME Aero’s capabilities could become a decisive factor in the commercial aviation landscape.
What is the significance of EME Aero’s second test cell? Which engines are serviced at the EME Aero facility? How does this expansion impact the local economy? What makes the GTF engine unique? How is EME Aero preparing for future engine technologies?
EME Aero’s Strategic Expansion: A New Era for GTF Engine Maintenance
Technological Advancements and Infrastructure Development
Second Test Cell: Engineering Excellence in 600 Days
Economic Impact and Workforce Expansion
Market Forces and Strategic Relevance
GTF Engine Demand and Market Share Dynamics
Geopolitical and Regulatory Influences
Conclusion: EME Aero’s Role in Aviation’s Future
FAQ
The second test cell increases EME Aero’s annual engine servicing capacity to over 500 units by 2028 and incorporates advanced diagnostic and environmental technologies.
EME Aero services Pratt & Whitney’s GTF engine family, including the PW1100G-JM, PW1500G, and PW1900G models.
The expansion supports over 1,200 jobs and generates approximately $220,000 in local economic value per engine serviced through supply chain and service sector engagement.
The GTF engine offers up to 20% better fuel efficiency and a 75% smaller noise footprint compared to older engines, making it a preferred choice for environmentally conscious airlines.
The facility is designed to accommodate future upgrades, including hybrid-electric propulsion testing and composite material diagnostics, ensuring long-term relevance.
Sources
Photo Credit: EME Aero