MRO & Manufacturing
SKYTRAC and Airbus Launch Real-Time Helionix Helicopter Alerts
SKYTRAC and Airbus Helicopters introduce real-time Helionix alerting for enhanced helicopter safety and predictive maintenance.
In the high-stakes world of aviation, particularly in helicopter operations, information is more than just data, it’s a critical lifeline. For decades, the standard has been to analyze an aircraft’s health after it has landed, downloading flight data to look for signs of stress or potential component failure. This reactive approach, while valuable, leaves a gap where critical events can unfold in real-time without ground crews being aware. The industry has been steadily moving towards a more proactive, connected model, where the aircraft communicates its status moment-by-moment, transforming safety protocols and operational efficiency.
This evolution takes a significant leap forward with the announcement of a new collaboration between SKYTRAC Systems Ltd. and Airbus Helicopters. The two aviation leaders have introduced a real-time alerting solution for helicopters equipped with the advanced Helionix avionics suite. This system is not just an incremental update; it represents a fundamental shift in how operators manage their fleets. By streaming critical health and usage data directly from the helicopter to ground personnel in real-time, the solution provides unprecedented situational awareness, enabling immediate decision-making and paving the way for a new standard in predictive maintenance.
The partnership leverages SKYTRAC’s expertise in satellite communications and Airbus’s cutting-edge avionics to address pressing industry needs. Initially driven by the stringent safety requirements of the offshore oil and gas sector, the benefits of this technology extend across all helicopter missions, including Helicopter Emergency Medical Services (HEMS), search and rescue, and corporate transport. It’s a move that promises to enhance safety, ensure compliance, and optimize the availability of some of the world’s most advanced rotorcraft.
At its core, the new system is a seamless integration of hardware and software designed to bridge the information gap between the cockpit and the operational base. It combines the sophisticated data-gathering capabilities of the Airbus Helionix avionics suite with the robust, global connectivity of SKYTRAC’s satellite communication hardware. This synergy creates a direct pipeline for critical aircraft information, ensuring that those on the ground have the same level of insight as the pilots, as events happen.
The technical foundation of the solution is the integration of SKYTRAC’s ISAT-200A hardware with the Helionix system. The Helionix suite, a digital cockpit environment, constantly monitors a vast array of aircraft parameters. The ISAT-200A, a compact and powerful satellite transceiver, captures this data and transmits it in real-time over the Iridium satellite network. This choice of network is crucial, as Iridium’s Low-Earth-Orbit (LEO) constellation provides true global coverage, including polar regions, and its L-band frequencies are highly resilient to adverse weather, ensuring reliable connectivity even in the remote and harsh environments where helicopters often operate.
Operators can now receive immediate alerts for a range of critical events. This includes Usage Monitoring System (UMS) exceedances, which indicate when an aircraft component has been subjected to stress beyond its designed limits. Other key alerts cover One Engine Inoperative (OEI) events, low fuel levels, caution panel warnings, and chip detection, which can signal early gearbox issues. Alongside these health alerts, the system continuously transmits the helicopter’s position, speed, and altitude, providing a complete operational picture at all times. For non-urgent data, the system also offers the option of post-flight offloading over cellular networks, providing a cost-effective way to manage large data logs.
This advanced alerting solution is being offered as a line-fit, factory-installed option on new orders of several of Airbus’s most popular helicopter models. The list includes the H135, H145, H160, and H175 rotorcraft. By integrating the system during manufacturing, Airbus ensures a seamless and certified installation, ready for operation upon delivery. This forward-looking approach highlights a commitment to building a new generation of helicopters that are connected and data-rich from day one, setting a new baseline for industry safety and efficiency standards.
“We are excited to be able to announce the availability of this solution in partnership with Airbus and highlight how we are committed to providing solutions that benefit the safety of air transport operators in the oil and gas industry and beyond.” – Rodrigo Lima, Director of Business Development, SKYTRAC
The development of this real-time alerting solution was not just a technological exercise; it was driven by clear and compelling industry demands. The primary catalyst is the need for helicopter operators, especially in the offshore oil and gas sector, to comply with increasingly rigorous safety standards. However, the implications of real-time data go far beyond mere compliance, fundamentally reshaping maintenance philosophies and enhancing safety for all types of missions. For operators supporting the oil and gas industry, the International Association of Oil & Gas Producers (IOGP) Report 690 is a critical document. It outlines a set of recommended practices for offshore helicopter operations, serving as a contractual standard for safety and efficiency. A key component of these recommendations involves Health and Usage Monitoring Systems (HUMS) to ensure the mechanical integrity of the aircraft. The ability to transmit HUMS and UMS data in real-time is a powerful tool for meeting and exceeding these standards. By providing immediate notification of exceedances, the SKYTRAC-Airbus solution allows operators to demonstrate proactive safety management and maintain compliance with the industry’s highest benchmarks.
Traditionally, HUMS data was downloaded and analyzed after a flight, a process that could take hours or even days. This meant that a potential issue might not be discovered until long after the aircraft was back in service. Real-time data transmission flips this model on its head. Ground crews can be alerted to a potential fault while the helicopter is still airborne, allowing them to prepare for maintenance the moment it lands. This proactive approach, known as condition-based maintenance, offers numerous advantages. It enables the early detection of faults, reducing the risk of in-flight failures. It also optimizes maintenance schedules, as work is performed when needed rather than at fixed intervals, which in turn reduces downtime and increases aircraft availability.
This shift from a reactive to a predictive maintenance culture is one of the most significant transformations in modern aviation. It not only enhances safety but also improves operational efficiency and the bottom line. By anticipating maintenance needs, operators can better manage parts inventory, schedule technicians, and keep their high-value assets flying more often. The real-time alerting solution is a key enabler of this evolution, providing the timely data needed to make informed, proactive decisions.
The collaboration between SKYTRAC and Airbus Helicopters on the real-time Helionix alerting solution is more than just a new product launch; it is a clear indicator of the future direction of the aviation industry. It demonstrates a powerful convergence of advanced avionics, global satellite connectivity, and data analytics to create a safer, more efficient operational environment. By providing immediate insight into an aircraft’s health and status, this technology empowers operators to move beyond traditional, reactive safety measures and embrace a proactive, data-driven approach.
As this technology becomes more widespread, we can expect to see its impact ripple across the entire aviation ecosystem. The principles of real-time monitoring and predictive maintenance, proven here in the demanding world of helicopter operations, will continue to be adopted in other aviation sectors. This move towards hyper-connectivity is not just about enhancing safety; it’s about building a more resilient, reliable, and intelligent global air transport system. The future of aviation is one where every aircraft is a connected node in a vast information network, and this partnership is a significant step toward realizing that vision.
Question: What is the new solution announced by SKYTRAC and Airbus Helicopters? Question: Which helicopter models are compatible with this solution? Question: Why is this technology particularly important for the oil and gas industry? Question: How does this system improve helicopter maintenance? Sources: SKYTRAC Pressroom
A New Era of Helicopters Safety: SKYTRAC and Airbus Unveil Real-Time Helionix Alerting
The Solution in Detail: How It Works
From Onboard Systems to Global Transmission
Availability Across Modern Airbus Fleets
The Driving Force: Compliance, Safety, and Proactive Maintenance
Meeting the Gold Standard: IOGP 690
The Dawn of Predictive Maintenance
Conclusion: A Connected Future for Aviation
FAQ
Answer: It is a real-time alerting solution for helicopters equipped with the Helionix avionics suite. The system uses SKYTRAC’s satellite communication hardware to transmit critical flight data and health alerts from the helicopter to ground crews instantly.
Answer: The solution is available as a factory-installed option on new Airbus H135, H145, H160, and H175 helicopters.
Answer: It helps operators comply with the stringent IOGP 690 standards for offshore helicopter operations, which recommend advanced health and usage monitoring. Real-time data transmission provides a powerful tool for proactive safety management required in this sector.
Answer: By providing real-time alerts on potential issues, it enables a shift from reactive to proactive, condition-based maintenance. Ground crews can prepare for repairs before the aircraft even lands, which reduces downtime, optimizes schedules, and enhances overall safety by catching potential faults early.
Photo Credit: SKYTRAC
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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