- TAP Air Portugal trialled lightweight basecoat technology reducing aircraft weight by up to 26 kg
- The system achieved a 36 pc reduction in basecoat film thickness versus traditional two-coat application
- Projected annual savings include 428.5 tonnes of fuel, over €500,000 in costs and 1,353 tonnes of CO₂
- Two A320 aircraft have received the coating, with plans for fleet-wide expansion
- The technology also improves sag resistance by 40 pc and simplifies the painting process
TAP Air Portugal has completed operational trials of a lighter basecoat technology for aircraft, with the new system capable of reducing weight by up to 26 kg per aircraft and contributing to annual fuel savings of approximately 428.5 tonnes. The tests, conducted using AkzoNobel Aerospace Coatings’ Aerobase UPD formulation, demonstrated a 36 pc reduction in the total thickness of the basecoat film compared with the traditional two-coat application process. The technology maintains the required standards of durability, appearance and finish quality for commercial aviation operations while eliminating the need for a second full coat of basecoat and associated intermediate drying stages.
Field tests on a TAP Air Portugal A320 aircraft resulted in a weight reduction of 24 kg, and a second A320 aircraft has since received the same coating, with expansion plans being drawn up for the entire fleet. The projected roll-out is expected to translate into annual cost savings of over half am euros and an estimated reduction of approximately 1,353 tonnes in CO₂ emissions per year. The improved formulation also provides approximately 40 pc greater resistance to sagging compared with the traditional two-coat system, contributing to greater consistency across different operating conditions in paint shops.
TAP Air Portugal currently operates one of the youngest fleets in the world, with Airbus next-generation NEO aircraft and 19 Embraer aircraft in its regional fleet. The airline flies from London Heathrow, London Gatwick, Manchester and Dublin to Lisbon and Porto, with onward connections to destinations in Brazil, Africa, the USA and Canada. João Carvalho, a Structural Engineer at TAP Air Portugal, noted that the results demonstrate how relatively small weight reductions, when applied consistently across the entire fleet, can contribute to long-term fuel and emissions savings whilst enhancing operational efficiency.
João Carvalho, a Structural Engineer at TAP Air Portugal, shared: “At TAP Air Portugal, we continually assess opportunities to improve operational efficiency and reduce our environmental impact across all our operations. The results achieved through this collaboration with AkzoNobel Aerospace Coatings demonstrate how relatively small weight reductions, when applied consistently across the entire fleet, can contribute to significant long-term fuel and emissions savings, whilst enhancing operational efficiency.”
