Wizz Air Plans to End Engine Groundings by 2027 Amid Pratt Whitney Crisis

Wizz Air Aims to End Engine-Related Groundings by 2027 Amid Ongoing Pratt & Whitney Turbofan Crisis

Wizz Air’s announcement that it expects to end engine-related aircraft groundings by the end of 2027 marks a critical juncture in the airline’s ongoing struggle with a manufacturing crisis that has disrupted the global aviation industry. The statement from Chief Financial Officer Ian Malin signals both hope and realism in the face of persistent issues with Pratt & Whitney’s geared turbofan (GTF) engines, which have grounded hundreds of aircraft worldwide. The root cause, defective engine components produced with contaminated powdered metal, has forced airlines to overhaul operational strategies, fleet management, and financial planning, while also prompting a broader industry reckoning with supply chain risks and maintenance practices.

The implications of this crisis are far-reaching. Airlines have been compelled to adapt quickly, manufacturers are under pressure to restore confidence and operational reliability, and the competitive dynamics within the commercial aviation sector have shifted. As Wizz Air and its peers navigate these challenges, the industry is witnessing an accelerated evolution in maintenance practices, risk management, and customer support frameworks. Understanding the genesis, scale, and ongoing response to the GTF engine crisis is essential for grasping its impact and the path to eventual resolution.

The Genesis and Scale of the Pratt & Whitney GTF Crisis

The Pratt & Whitney PW1000G geared turbofan engine was introduced as a breakthrough in aviation technology, promising significant improvements in fuel efficiency and noise reduction. However, a critical flaw was discovered: contaminated powdered metal used in manufacturing certain engine components between late 2015 and 2021. This contamination resulted in microscopic defects, particularly in the high-pressure turbine disks, which could develop into dangerous cracks and potentially cause uncontained engine failures.

The full extent of the problem became apparent in 2023, when Pratt & Whitney expanded its recall to include all 3,000 PW1100G engines in service globally. These engines power a substantial portion of the Airbus A320neo family, creating a ripple effect across airlines that rely on this aircraft type. The recall required lengthy inspections, each taking up to 300 days, and led to an average of 350 aircraft being grounded at any given time through at least 2026, with the highest concentration of groundings in early 2024.

Financially, the crisis has been monumental. RTX, Pratt & Whitney’s parent company, estimates the total cost, including unscheduled work, replacement parts, and operator compensation, at $6 to $7 billion. RTX itself expects to pay $2.9 billion in compensation to affected customers, reflecting the scale and complexity of the recall. These costs represent one of the largest product recall events in aerospace history and have had a material impact on both manufacturers and operators.

“The recall’s magnitude is unprecedented, requiring inspections that take between 250 to 300 days to complete, leading to an average of 350 airplanes being grounded through 2026.”

Wizz Air’s Operational and Financial Challenges

Wizz Air stands out as one of the most affected airlines, with its operational model and fleet composition making it particularly vulnerable to the GTF engine disruption. As of mid-2024, the airline had 41 aircraft grounded due to engine issues, approximately 15% of its total fleet. Although this number has since declined to 38, it remains a significant operational constraint, especially for a carrier built on high utilization and rapid growth.

To mitigate the disruption, Wizz Air has doubled its spare engine pool and overhauled maintenance cycles. The airline has also shifted its approach to fleet planning, emphasizing tighter collaboration with Pratt & Whitney and more predictive, data-driven maintenance strategies. These adjustments have exposed structural weaknesses in the engine aftermarket and placed additional pressure on both internal and external maintenance resources.

The financial impact has been severe. For the year ending March 2025, Wizz Air reported a 41.5% year-over-year drop in net profit to €213.9 million, while operating profit fell by 62% to €167.5 million. Despite a modest rise in annual revenues to €5.3 billion, non-fuel unit costs surged nearly 20%, largely due to increased maintenance, repair, and material expenses. The crisis has also forced Wizz Air to reduce its annual passenger growth target and delay new aircraft deliveries, constraining both its short-term flexibility and long-term expansion plans.

Strategic Pivots and Network Restructuring

Wizz Air has responded to the crisis by fundamentally rethinking its network and fleet strategy. The airline recently exited the Abu Dhabi market, citing geopolitical risks and environmental factors that worsen engine wear. Aircraft previously based in Abu Dhabi have been redeployed to European routes, while older A320ceo models are being parked during off-peak periods to conserve maintenance resources.

This strategic shift reflects a broader move toward maintenance flexibility and risk mitigation. By pausing utilization of older, less efficient aircraft, Wizz Air is prioritizing operational resilience over aggressive growth. The airline’s ability to rapidly adapt its network and fleet utilization has been tested, forcing a shift from opportunistic expansion to a more conservative, maintenance-driven approach.

The network restructuring has also affected Wizz Air’s competitive positioning. Reduced operational flexibility has limited the airline’s ability to capitalize on new market opportunities, a key advantage for low-cost carriers. Instead, Wizz Air is now dependent on the timely completion of engine repairs and long-term planning with manufacturers and maintenance partners.

“The airline has been compelled to double its spare engine pool and reconfigure maintenance cycles, creating mounting pressure on internal planning and third-party maintenance, repair, and overhaul partners.”

Financial Performance and Credit Implications

The ongoing engine crisis has placed significant strain on Wizz Air’s financial position and creditworthiness. In July 2025, Fitch downgraded the airline’s credit rating from BB+ to BB, citing weaker operating performance as a direct result of the engine issues. Despite some revenue growth, the airline’s profitability and cost structure have been fundamentally altered by increased maintenance expenses and lost capacity.

Other airlines have faced similar challenges. Spirit Airlines, for example, has negotiated compensation agreements with Pratt & Whitney, including monthly credits through 2025. These arrangements provide some financial relief but require airlines to release further claims, locking in both parties to a defined compensation structure while the repair program continues.

For manufacturers, the crisis has forced accelerated investment in maintenance, repair, and overhaul (MRO) capacity and technological innovation to reduce repair times. RTX has expanded its MRO network, including new partnerships with Delta TechOps and MTU Aero Engines, and is deploying additive manufacturing techniques to speed up repairs and reduce costs.

Industry-Wide Impact and Technical Details

The GTF engine crisis has affected airlines worldwide, not just Wizz Air. Spirit Airlines has seen up to 30% of its A320neo-family fleet grounded, while Indian carrier GoFirst suspended operations and filed for bankruptcy, directly attributing its collapse to engine reliability problems. Swiss and Air Baltic have also grounded portions of their A220 fleets due to related engine issues, and EgyptAir sold its entire A220-300 fleet because of persistent reliability challenges.

The technical challenges stem from both the contaminated powdered metal issue and other design flaws. The GTF engine’s innovative geared design enables higher efficiency and lower noise but also introduces new failure modes. In addition to the powdered metal contamination, earlier problems included knife edge seal failures and excessive corrosion in high-pressure compressor components, further complicating maintenance and reliability.

Pratt & Whitney’s response has included a comprehensive fleet management plan, expanded MRO capacity, and significant investment in new repair technologies. The company’s compensation framework, valued at $6–7 billion, is one of the largest in aerospace history and includes direct payments, credits, and support to affected airlines. These measures aim to restore operational reliability and rebuild customer confidence, but the resolution timeline extends into 2027, with ongoing risks and uncertainties.

“The crisis has accelerated broader industry trends toward maintenance digitization and predictive analytics. Airlines are investing heavily in data-driven maintenance approaches and closer collaboration with engine manufacturers.”

Future Outlook and Industry Implications

The path to recovery will be gradual. Wizz Air’s goal of ending engine-related groundings by 2027 is ambitious but reflects the current pace of repairs and capacity expansion. As of early 2024, the number of grounded aircraft industry-wide peaked at around 650 before stabilizing at 300–350, where it is expected to remain until 2026. Pratt & Whitney has reported a modest improvement in engine turnaround times, but the repair backlog remains substantial.

Looking ahead, the crisis is likely to influence engine selection, fleet planning, and risk management strategies for years to come. Airlines may prioritize supply chain diversity and avoid overreliance on single-source engine suppliers. Meanwhile, the adoption of predictive maintenance and advanced repair technologies could improve long-term operational resilience and efficiency. The experience has also underscored the importance of robust quality control in aerospace manufacturing and the potential consequences of supply chain lapses.

Conclusion

The Pratt & Whitney GTF engine crisis stands as a defining challenge for the aviation industry, highlighting vulnerabilities in manufacturing, maintenance, and supply chain management. Wizz Air’s projection that it will resolve engine-related groundings by 2027 provides a roadmap for recovery, but the journey involves ongoing operational, financial, and strategic adjustments. The crisis has forced airlines to rethink growth strategies, invest in maintenance capabilities, and collaborate more closely with manufacturers.

Ultimately, the lessons learned from this episode will shape the future of aircraft design, manufacturing standards, and airline operations. While the costs have been high, both financially and operationally, the industry’s response demonstrates resilience and a commitment to safety and reliability. As the sector moves forward, the innovations and adaptations born out of necessity may yield long-term benefits, strengthening the foundations of global aviation.

FAQ

What caused the Pratt & Whitney GTF engine crisis?
The crisis was caused by contaminated powdered metal used in manufacturing engine components between 2015 and 2021, leading to microscopic defects and potential engine failures.

How has Wizz Air been affected by the engine issues?
Wizz Air has had up to 41 aircraft grounded, representing about 15% of its fleet, and has faced significant financial and operational challenges, including reduced profitability and delayed growth plans.

When is the crisis expected to be resolved?
Wizz Air’s CFO has stated the airline aims to resolve all engine-related groundings by the end of 2027, though this timeline depends on ongoing repair and maintenance efforts.

What compensation have airlines received?
Affected airlines have received compensation agreements from Pratt & Whitney and RTX, including direct payments, credits, and other financial support, with the total compensation framework valued at $6–7 billion.

What are the broader industry implications?
The crisis has prompted airlines to reassess their maintenance strategies, diversify engine sourcing, and invest in predictive maintenance and advanced repair technologies.

Sources:
Reuters