MRO & Manufacturing
Riyadh Air Signs Long-Term APU Support Deal with EPCOR for Fleet Reliability
Riyadh Air partners with EPCOR to maintain APS5000 APUs on Boeing 787s, enhancing fleet reliability and supporting Saudi Vision 2030 goals.
Riyadh Air, Saudi Arabia’s new national airline, has taken a significant step toward operational readiness by signing a long-term agreement with EPCOR, a subsidiary of Air France Industries KLM Engineering & Maintenance (AFI KLM E&M). The partnership focuses on comprehensive maintenance support for the APS5000 Auxiliary Power Units (APUs) installed on Riyadh Air’s Boeing 787 Dreamliner fleet.
This deal is a cornerstone in Riyadh Air’s broader ambition to become a leading global carrier aligned with the Kingdom’s Vision 2030. It also highlights the increasing reliance on predictive maintenance and digital technologies in the aviation Maintenance, Repair, and Overhaul (MRO) sector. EPCOR’s expertise in APS5000 systems and its use of the Prognos® predictive analytics platform offer Riyadh Air a strategic advantage in operational efficiency and reliability.
As the airline industry continues to rebound from pandemic-related disruptions, strategic partnerships like this one are becoming essential for mitigating supply chain risks and ensuring long-term fleet availability. This article explores the details of the agreement, its implications, and its relevance in the context of global aviation trends.
The APS5000 is an all-electric APU developed by Pratt & Whitney specifically for the Boeing 787 Dreamliner. Unlike traditional APUs, the APS5000 is designed to support the 787’s “more-electric” architecture, which replaces many hydraulic and pneumatic systems with electrical ones. This design enhances fuel efficiency and reduces emissions.
Key features of the APS5000 include a bleedless design, a single-shaft variable-speed turbine, and the ability to operate at altitudes up to 43,100 feet. These attributes make it a critical component for the 787’s performance, particularly on long-haul international routes where reliability is non-negotiable.
Given the complexity and importance of the APS5000, maintaining its operational readiness is essential. This is where EPCOR’s expertise becomes invaluable, offering Riyadh Air a partner with deep technical knowledge and global experience in APU maintenance.
Launched in 2023, Riyadh Air is a central pillar of Saudi Arabia’s Vision 2030, which aims to diversify the economy and position the Kingdom as a global logistics and tourism hub. The airline has ambitious plans to connect over 100 destinations by 2030.
To support this vision, Riyadh Air has placed orders for 72 Boeing 787-9 Dreamliners and 25 Airbus A350-1000s. These wide-body aircraft will serve as the backbone of its long-haul operations. Additionally, the airline is expected to utilize narrow-body aircraft like the Airbus A321neo for regional connectivity. The agreement with EPCOR ensures that the APS5000 units on the Dreamliner fleet receive consistent, high-quality maintenance, reducing the risk of unplanned groundings and enhancing overall fleet reliability.
“This long-term partnership ensures our fleet receives the highest standard of technical support… aligned with Saudi Arabia’s Vision 2030.”, Martin Eiba, Acting COO, Riyadh Air
The partnership between Riyadh Air and EPCOR is comprehensive in scope. It includes full Maintenance, Repair, and Overhaul (MRO) services for the APS5000 units, ensuring end-to-end support for the airline’s Dreamliner fleet. This includes on-wing support, LRU (Line Replaceable Unit) coverage, and modification services.
One of the standout features of the agreement is the integration of EPCOR’s Prognos® platform. This predictive maintenance tool uses advanced analytics to monitor the health of APUs in real-time, allowing for early detection of potential issues and minimizing unscheduled maintenance events.
By leveraging Prognos®, Riyadh Air can optimize maintenance schedules, reduce operational disruptions, and extend the lifecycle of its APU assets. This aligns with broader industry trends favoring digital and data-driven MRO solutions.
EPCOR brings a wealth of experience to the table. As a subsidiary of AFI KLM E&M, the company supports over 90 airlines worldwide and manages more than 1,000 APUs annually. EPCOR is also responsible for over 30% of global APS5000 maintenance, making it one of the most experienced providers in this niche sector.
The company holds exclusive licenses for several APU models, including the Honeywell 331-350 and 131-9C. This specialization allows EPCOR to offer tailored solutions that meet the unique needs of different aircraft platforms.
Its track record with airlines such as Air Canada, Gulf Air, and Kuwait Airways underscores its ability to deliver consistent, high-quality MRO services. For Riyadh Air, this partnership provides a level of assurance that is particularly valuable during its formative years.
The deal offers multiple benefits for Riyadh Air. First, it ensures high fleet availability by reducing APU-related downtime. With LRU coverage and on-wing support, the airline can maintain tight operational schedules without compromising safety or reliability. Second, the use of predictive maintenance helps in cost management by avoiding expensive emergency repairs and optimizing part replacement cycles. This is especially important for a new airline operating on a tight budget and aggressive expansion timeline.
Lastly, the partnership supports Riyadh Air’s long-term strategy of building a world-class airline rooted in technological innovation and operational excellence.
The global APU market is witnessing a shift toward electric systems and sustainability. Models like the APS5000 are gaining traction due to their efficiency and lower environmental impact. This aligns with broader industry goals of reducing carbon emissions and improving fuel economy.
Simultaneously, the MRO sector is embracing digital transformation. Predictive analytics platforms like Prognos® are becoming standard tools for optimizing maintenance operations. These technologies not only reduce costs but also enhance safety and reliability.
By adopting these innovations, Riyadh Air positions itself at the forefront of modern aviation practices, setting a benchmark for other emerging carriers.
Riyadh Air is more than just a new airline; it is a strategic vehicle for achieving Saudi Arabia’s Vision 2030 objectives. The Kingdom aims to increase annual passenger traffic to 330 million and become a top-five global air transit hub by 2030.
Investments in fleet expansion, digital platforms, and international partnerships are all part of this roadmap. The EPCOR agreement fits squarely within this framework, ensuring that Riyadh Air’s technical foundation is as robust as its commercial ambitions.
Furthermore, the deal contributes to job creation and economic diversification by fostering a high-tech, service-oriented aviation sector within the Kingdom. Despite its promise, Riyadh Air faces several challenges, including aircraft delivery delays and the complexities of launching a new airline in a competitive market. However, securing reliable MRO partnerships helps mitigate some of these risks.
Looking ahead, Riyadh Air may explore similar agreements for its Airbus A350-1000 fleet and expand its digital ecosystem to include customer-facing platforms for booking, accommodations, and transportation.
As the airline prepares for its official launch, its collaboration with EPCOR serves as a model for how strategic planning and technical partnerships can drive success in the aviation industry.
The long-term APU support agreement between Riyadh Air and EPCOR represents a critical milestone in the airline’s journey toward full operational readiness. By entrusting a significant component of its fleet maintenance to a globally recognized expert, Riyadh Air ensures that its Boeing 787 Dreamliners will be supported by best-in-class technical services.
More broadly, the deal exemplifies how emerging airlines can leverage strategic partnerships to navigate complex operational landscapes. As Riyadh Air moves closer to its 2025 launch, its focus on innovation, reliability, and global collaboration positions it as a strong contender in the international aviation arena.
What is the APS5000 APU? Who is EPCOR? How does predictive maintenance benefit Riyadh Air? Aviation Business News, EPCOR, Boeing, Vision 2030 Saudi Arabia
Riyadh Air and EPCOR Sign Long-Term APU Support Deal: A Strategic Leap for Fleet Reliability
Background: Understanding APS5000 and Riyadh Air’s Fleet Strategy
The APS5000 APU: Backbone of the Boeing 787
Riyadh Air’s Vision and Fleet Expansion
Core Components of the EPCOR Agreement
Scope of Services
EPCOR’s Global Expertise
Operational and Strategic Benefits
Industry Context and Broader Implications
Trends in the APU and MRO Market
Saudi Arabia’s Vision 2030 and Aviation Goals
Challenges and Future Outlook
Conclusion
FAQ
The APS5000 is an all-electric Auxiliary Power Unit developed by Pratt & Whitney for the Boeing 787 Dreamliner. It supports the aircraft’s electrical systems and enhances fuel efficiency.
EPCOR is a subsidiary of AFI KLM E&M that specializes in APU and pneumatic component maintenance. It supports over 90 airlines globally and is a leading provider of APS5000 maintenance services.
Predictive maintenance, enabled by EPCOR’s Prognos® platform, helps Riyadh Air anticipate technical issues before they occur, reducing downtime and maintenance costs.Sources
Photo Credit: Riyadh Air
MRO & Manufacturing
ITP Aero to Acquire Aero Norway, Expanding CFM56 MRO Services
ITP Aero signs agreement to acquire Aero Norway, enhancing aftermarket capabilities for CFM56 engines and expanding its European MRO presence.
ITP Aero, a global leader in aerospace propulsion, has signed a binding agreement to acquire Aero Norway, a specialized maintenance, repair, and overhaul (MRO) provider focused on CFM56 engines. According to the company’s official announcement, the transaction is expected to close during the first half of 2026, subject to customary regulatory approvals.
The acquisition represents a significant expansion of ITP Aero’s aftermarket capabilities. By integrating Aero Norway’s facility in Stavanger, Norway, ITP Aero aims to reinforce its status as a leading independent player in the aerospace services sector. The move follows a trajectory of aggressive growth for the Spanish propulsion company since its acquisition by Bain Capital in 22.
Aero Norway operates out of a facility at Sola Airport in Stavanger, employing a workforce of over 200 skilled technicians. The company has established a reputation for high-quality engine maintenance, specifically for the CFM56 engine family, serving a global client base of airlines, lessors, and asset managers.
In its press statement, ITP Aero highlighted that the two companies possess “highly complementary strengths.” The deal combines Aero Norway’s deep expertise in engine overhaul with ITP Aero’s existing engineering capabilities and component repair infrastructure. This synergy is designed to offer a more comprehensive suite of services to the aftermarket sector.
This agreement is the latest in a series of strategic moves by ITP Aero. In 2023, the company acquired BP Aero in the United States and was recently selected to join Pratt & Whitney’s GTF MRO network. These steps are part of a broader “2030 Strategic Plan” which aims to double the size of the business and increase the global workforce by 50% by the end of the decade.
While the press release focuses on corporate synergies, the acquisition underscores a critical trend in the current aviation landscape: the extended dominance of the CFM56 engine. As new-generation engines like the LEAP and GTF face supply chain delays and durability challenges, airlines are keeping older aircraft powered by CFM56 engines in service longer than originally planned.
Industry data suggests that approximately 20,000 CFM56 engines will remain in service through 2025. Consequently, the demand for maintenance shop visits is projected to peak between 2025 and 2027. By acquiring a specialist shop like Aero Norway, ITP Aero is effectively positioning itself to capture high-value work during this period of “structural undersupply” in the narrowbody market. This “Golden Tail”, the long, profitable tail end of an engine program’s lifecycle, provides a stable revenue runway for MRO providers capable of handling heavy overhauls. The crossover point where new-generation engine shop visits outnumber CFM56 visits is not expected until later in the decade, making capacity for legacy engines a premium asset today.
Leadership from both organizations emphasized the value of combining their respective technical strengths. Eva Azoulay, CEO of ITP Aero Group, described the agreement as a key component of the company’s roadmap.
“The signing of this binding acquisition agreement marks a significant milestone in our strategic roadmap. This acquisition reinforces our ambition to become a leading independent player in the aerospace aftermarket.”
, Eva Azoulay, CEO of ITP Aero Group
Neil Russell, CEO of Aero Norway, noted that the merger would unlock synergies beneficial to their customer base.
“By combining the complementary strengths of ITP Aero and Aero Norway, we will unlock significant synergies that enhance our competitiveness and deliver even greater value to our customers.”
, Neil Russell, CEO of Aero Norway
ITP Aero reports that it has tripled its earnings since 2022 and is currently implementing a long-term business plan that spans civil, defense, and MRO segments. The company was advised on legal M&A matters regarding this transaction by Baker McKenzie.
Pending regulatory clearance, the integration of Aero Norway into the ITP Aero Group will finalize in 2026, solidifying the company’s footprint in the European MRO market.
Sources:
ITP Aero to Acquire Aero Norway, Strengthening Position in CFM56 Aftermarket
Strategic Expansion in the MRO Sector
AirPro News Analysis: The “Golden Tail” of the CFM56
Executive Commentary
Future Outlook
Photo Credit: ITP Aero
MRO & Manufacturing
AkzoNobel Invests €50 Million to Upgrade US Aerospace Coatings Facilities
AkzoNobel invests €50 million to expand and modernize aerospace coatings production in Illinois and Wisconsin, enhancing capacity and supply chain resilience.
This article is based on an official press release from AkzoNobel.
AkzoNobel has officially announced a significant investments of €50 million (approximately $52–55 million) to modernize and expand its aerospace coatings capabilities in North America. According to the company’s announcement on December 18, 2025, the project will focus on upgrading its flagship manufacturing facility in Waukegan, Illinois, and establishing a new distribution center in Pleasant Prairie, Wisconsin.
This strategic move aims to increase production capacity and shorten lead times for airline and Maintenance, Repair, and Operations (MRO) customers. By enhancing its supply chain infrastructure, AkzoNobel intends to address the growing demand for air travel and the subsequent need for advanced aerospace coatings.
The investment centers on the Waukegan facility, which currently serves as AkzoNobel’s largest aerospace coatings production site globally. The site employs approximately 200 people and houses a dedicated color center. According to the press release, the capital injection will fund the installation of new machinery and automated processes designed to handle larger batch sizes.
To further optimize operations, the company is relocating its warehousing and distribution activities to a new facility in Pleasant Prairie, Wisconsin. This relocation is intended to free up floor space at the Waukegan plant, allowing for a focus on complex, customized chemical manufacturing.
Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings, emphasized the forward-looking nature of the investment:
“This investment will increase our comprehensive North American supply capability and solidify our position as a frontrunner in the aerospace coatings industry. Demand for air travel is expected to grow significantly… and we want to make sure our customers are able to meet that demand.”
A key component of the upgrade is the introduction of a “Rapid Service Unit” dedicated to faster turnaround times for the MRO market. The company states that the new infrastructure will include a “liquid pre-batch area” and “high-speed dissolvers” to accelerate production.
Martijn Arkesteijn, Global Operations Director for AkzoNobel Aerospace Coatings, noted that these improvements are designed to enhance flexibility for customers: “We’ll be able to provide current and future customers with even more flexibility through the delivery of large batch sizes, better responsiveness to market needs and shorter lead time for color development.”
While AkzoNobel’s announcement focuses on internal efficiency, this investment arrives during a period of intensified competition within the North American aerospace sector. Earlier in 2025, rival manufacturer PPG announced a massive $380 million investment to construct a new aerospace coatings plant in Shelby, North Carolina.
In our view, AkzoNobel’s strategy differs significantly from its competitor’s greenfield approach. Rather than building new capacity from scratch, AkzoNobel is executing a targeted upgrade of existing assets. This “efficiency war” suggests that the company is betting on agility and technology upgrades, specifically the ability to deliver custom colors and small batches quickly via its new Rapid Service Unit, rather than simply expanding raw volume output.
The upgraded facilities are also aligned with the aviation industry’s push for decarbonization. AkzoNobel highlighted that the investment supports the production of its “Basecoat/Clearcoat” systems, which are lighter than traditional coatings. Reducing paint weight is a critical factor for airlines seeking to lower fuel consumption and carbon emissions.
Furthermore, the new automated processes are expected to reduce chemical waste and solvent use. The facility upgrades will likely support the increased production of chromate-free primers, meeting stricter regulatory requirements in both the United States and the European Union.
By localizing more storage and production capacity in North America, AkzoNobel also aims to bolster supply chain resilience, addressing vulnerabilities exposed during the post-pandemic aviation recovery.
AkzoNobel Announces €50 Million Upgrade to US Aerospace Coatings Operations
Strategic Expansion in Illinois and Wisconsin
Operational Efficiency and the “Rapid Service Unit”
AirPro News Analysis: The Competitive Landscape
Sustainability and Technology Integration
Sources
Photo Credit: AkzoNobel
MRO & Manufacturing
GE Aerospace Deploys 180 Engineers for Holiday Flight Operations
GE Aerospace positions 180 Field Service Engineers in 34 countries to prevent aircraft groundings and manage winter maintenance challenges during peak holiday travel.
While millions of travelers settle in for holiday downtime, the global aviation industry enters its most critical operational window. According to AAA projections, approximately 122.4 million Americans traveled 50 miles or more from home during the 2024-2025 holiday season, with air travel seeing a projected 2.3% increase in domestic flyers. Behind this surge lies a largely invisible workforce dedicated to preventing cancellations before they happen.
According to an official press release from GE Aerospace, the company deployed 180 Field Service Engineers (FSEs) to 34 countries specifically to support Airlines customers during this peak period. These engineers are “embedded” directly with airlines and airframers, working on tarmacs and in hangars to mitigate technical risks that could otherwise ground fleets during the busiest weeks of the year.
The role of an FSE goes beyond standard maintenance; it involves proactive problem-solving under strict time constraints. GE Aerospace describes these teams as being on the front lines, ensuring that both passenger jets and cargo freighters remain operational despite the strain of high-cycle usage and winter weather.
Jordan Mayes, a Regional Leader for GE Aerospace Commercial Field Service in Western Europe and Africa, highlighted the intensity of the holiday operational tempo in the company’s statement:
“The sense of urgency is more elevated than normal… And often there are fewer hands to do the work.”
, Jordan Mayes, GE Aerospace Regional Leader
This urgency is driven not just by passenger volume, but by a booming air cargo sector. Industry data indicates that air cargo volumes saw double-digit growth in late 2024, driven by e-commerce demands and shipping disruptions in the Red Sea. Stephane Petter, a Regional Leader for Central/Eastern Europe and Central Asia, noted that the stakes for cargo are often underestimated.
“An issue with a grounded or delayed passenger aircraft might delay 350 people. With a cargo plane, thousands of parcels might be delayed, so the downstream customer impact is potentially greater.”
, Stephane Petter, GE Aerospace Regional Leader
To illustrate the impact of embedded engineers, GE Aerospace shared a specific operational success story involving Alaa Ibrahim, the Middle East regional leader. His team was monitoring a Boeing 787 Dreamliner equipped with GEnx-1B engines. The engineers identified a minor clamp repair that was necessary to keep the engine compliant. The engine was only four cycles (flights) away from a mandatory 500-cycle inspection limit. If the limit was reached without the repair, the aircraft would be grounded, a disastrous outcome during peak holiday scheduling.
Instead of waiting for a forced grounding, Ibrahim’s team identified a six-hour window in the aircraft’s schedule. They performed the inspection and repair proactively, ensuring the aircraft remained available for service without disrupting the airline’s timetable.
Beyond scheduling pressures, FSEs must contend with the physical realities of winter aviation. Industry reports highlight that “cold soak”, where an aircraft sits in freezing temperatures for extended periods, presents unique mechanical challenges. Oil can thicken, and seals can shrink or become brittle.
According to technical data regarding modern engines like the CFM LEAP, specific warm-up protocols are required to thermally stabilize the engine before takeoff power is applied. Maintenance teams often switch to lower-viscosity fluids and rigorously check breather tubes for ice accumulation. If a breather tube freezes due to condensation, it can pressurize the engine and cause seal failures.
The deployment of these 180 engineers highlights a broader shift in aviation maintenance from reactive repairs to predictive intervention. By utilizing digital tools that monitor engine health in real-time, often referred to as “Flight Deck” principles, engineers can detect vibration trends or temperature spikes before they trigger a cockpit warning.
We observe that this strategy is particularly vital during the holidays. When load factors are near 100%, airlines have zero spare aircraft to absorb a cancellation. The ability of FSEs to turn a potential “aircraft on ground” (AOG) event into a scheduled maintenance task during a layover is the difference between a smooth operation and a headline-making travel meltdown.
All Sleigh, No Delay: How Field Service Engineers Keep Holiday Fleets Airborne
The “Invisible Elves” of Aviation
Operational Wins: The GEnx-1B “Save”
Technical Challenges in Winter Operations
AirPro News Analysis: The Shift to Predictive Maintenance
Frequently Asked Questions
Sources
Photo Credit: GE Aerospace
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