TAP Air Portugal Trials AkzoNobel Lightweight Aircraft Basecoat

TAP Air Portugal (TP) and AkzoNobel Aerospace Coatings have concluded operational trials of a new lightweight aircraft basecoat, achieving a 24-kilogram weight reduction on an Airbus A320 and prompting a planned fleet-wide rollout.

Announced in a joint press release on July 28, 2026, the Aerobase UPD formulation eliminates a full paint cycle and reduces total basecoat film thickness by 36 percent compared to traditional two-coat applications. The technology targets incremental weight reductions to lower fuel consumption and carbon emissions across Commercial-Aircraft operations.

Technical enhancements and paint shop efficiency

The Aerobase UPD system utilizes a validated cross-coat application technique that achieves required hiding power and finish quality in a single basecoat cycle. This eliminates the need for a second full basecoat layer and its associated flash-off stages. The simplified process removes an entire paint cycle, increasing operational productivity for applicators.

According to AkzoNobel, the enhanced formulation delivers approximately 40 percent greater sag resistance than traditional two-layer systems. This improvement is designed to increase consistency and repeatability across varying paint shop conditions and applicator experience levels. The product is certified to AMS3095 standards for global mixed-fleet Maintenance, Repair, and Overhaul (MRO) operations and integrates with existing Aerobase activators and hardeners.

“By reducing total film build and simplifying the application process, Aerobase UPD helps operators lower aircraft weight, improve paint shop productivity and maintain the high-quality finish standards required across commercial aviation fleets,” said Aurore Bournazel, Segment Manager OEM, MRO & Airlines at AkzoNobel Aerospace Coatings.

Fleet-wide economic and environmental projections

Field testing on a TAP Air Portugal Airbus A320 confirmed a 24-kilogram weight reduction, nearing the maximum 26-kilogram reduction projected for the technology. Following the initial trial, the Airlines has recoated a second Airbus A320 and is developing rollout plans to extend the lightweight basecoat across its fleet.

Based on projected fleet-wide implementation, TAP Air Portugal estimates the lighter coating will save approximately 428.5 tonnes of fuel annually. This reduction translates to more than 500,000 euros in annual cost savings and an estimated decrease of 1,353 tonnes of carbon dioxide emissions.

“The results achieved through this collaboration with AkzoNobel Aerospace Coatings demonstrate how relatively small weight reductions, when applied consistently across aircraft fleets, could contribute to meaningful long-term fuel and emissions savings, while also supporting operational efficiency,” said João Carvalho, Structures Engineer at TAP Air Portugal.

AirPro News analysis

We view this development as a clear example of how airlines are targeting marginal gains to meet stringent decarbonization targets. While a 24-kilogram reduction on a narrowbody aircraft like the Airbus A320 represents a fraction of its maximum takeoff weight, the cumulative effect across thousands of flight cycles yields material financial and environmental benefits. For European carriers operating under the European Union Emissions Trading System (EU ETS), reducing fuel burn directly lowers compliance costs. The elimination of a full paint cycle also offers MRO providers a tangible reduction in aircraft downtime, which is a critical metric in current constrained maintenance environments.

Sources: TAP Air Portugal via Cision News