AkzoNobel Aerospace Coatings and TAP Air Portugal have successfully completed operational trials of a lighter aircraft basecoat technology that can reduce coating weight by up to 26kg per aircraft, supporting the airline’s ongoing focus on operational efficiency, fuel savings and lower emissions.

Using AkzoNobel Aerospace Coatings’ Aerobase UPD formulation, the trials demonstrated that the system can reduce total basecoat film thickness by 36% compared with a traditional two-coat application process, while maintaining the durability, appearance and finish quality standards required for commercial aviation operations.

Based on projected fleet-wide implementation, the lighter coating technology is expected to contribute to annual fuel savings of approximately 428.5 tonnes, resulting in annual cost savings of more than half a million euros and an estimated reduction of approximately 1,353 tonnes of CO₂ emissions.

Proven results with TAP Air Portugal

Field testing on a TAP Air Portugal A320 aircraft achieved a 24kg weight reduction. Following these results, a second A320 has also been recoated, with rollout plans being put in place to extend the lightweight basecoat across the fleet.

Key trial outcomes included:

1. 24kg weight reduction achieved on a TAP Air Portugal A320 during field testing.
2. 36% reduction in total basecoat film thickness versus a traditional two-coat application process.
3. Approximately 428.5 tonnes of projected annual fuel savings across the fleet.
4. An estimated annual reduction of approximately 1,353 tonnes of CO₂ emissions.

How Aerobase UPD improves MRO efficiency

The Aerobase UPD formulation used in the trials builds on AkzoNobel Aerospace Coatings’ proven Aerobase platform through formulation and application enhancement designed to improve film build control, sag resistance and process repeatability in real-world paint shop operations.

Using a validated cross-coat application technique, the Aerobase UPD enables the required hiding power and finish quality to be achieved through a single basecoat application cycle. This eliminates the need for a second full basecoat layer and associated flash-off stages.

In addition to reducing aircraft operating weight, the simplified application process also delivers operational productivity benefits for applicators by removing one whole paint cycle.

The enhanced formulation also delivers approximately 40% greater sag resistance compared with the traditional twolayer system, helping improve consistency and repeatability across varying operational paint shop conditions and applicator experience levels.

Supporting airline efficiency and sustainability goals

For TAP Air Portugal, the results highlight how targeted technical improvements can contribute to broader aviation efficiency and sustainability objectives.

João Carvalho, Structures Engineer at TAP Air Portugal, said: “At TAP Air Portugal, we continuously evaluate opportunities to improve operational efficiency and reduce environmental impact across our operations

“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.”

Aurore Bournazel, Segment Manager OEM, MRO & Airlines at AkzoNobel Aerospace Coatings, added: “This program with TAP Air Portugal demonstrates how incremental innovations in coatings technology can deliver measurable operational benefits and emissions savings for airlines.

“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.

“The aviation industry is focused on identifying practical opportunities to improve efficiency and reduce emissions, and coatings technology can play an important role in supporting those wider sustainability ambitions.”

Certified for mixed-fleet MRO operations

Aerobase UPD is certified to AMS3095 standards for global mixed-fleet MRO operations and integrates with the upgraded Aerobase activator and existing Aerobase hardeners, enabling straightforward implementation within existing paint shop processes.