Regional airline KLM Cityhopper has begun the gradual reactivation of its Embraer E195-E2 fleet after parts of the aircraft were stored at Twente Airport for over a year. The temporary grounding was due to severe shortages in the supply and maintenance of the Pratt & Whitney Geared Turbofan (GTF) engines.
These technical challenges not only affected the Dutch airline but also led to aircraft shortages for various operators worldwide. A total of four aircraft had to be transferred to long-term storage, with engines, auxiliary power units, and batteries being removed to free up limited resources for continued flight operations.
To protect the aircraft from weathering and corrosion during their storage period, a special preservation process was employed. The jets were completely wrapped in a protective plastic film, a process known in the industry as "cocooning." This sealing covered both the outer shell and sensitive internal components and was carried out according to strict specifications from the manufacturer, Embraer. Preparing each aircraft for this storage took approximately six weeks to ensure the integrity of the aircraft structure and remaining systems during their time outdoors.
The recommissioning process has now begun, as the availability of the necessary engine components has stabilized. The first aircraft, registered under PH-NXA, is currently being unpacked at Twente Airport and prepared for its ferry flight. Reactivation is a time-consuming undertaking, taking approximately two months per aircraft. In addition to removing protective coverings and reinstalling landing gear and engines, the aircraft must undergo comprehensive technical inspections. The airline is also using this downtime for upgrades, such as installing Wi-Fi systems in the cabin, to bring the aircraft up to the standard of the rest of the fleet.
Two of the stored aircraft are already in the active preparation phase, while the remaining two are scheduled to be reintegrated into active flight operations by autumn 2026. This capacity expansion is of strategic importance for KLM Cityhopper to restore regional connectivity from its Amsterdam Schiphol hub to the planned level. The industry is closely monitoring the return of the GTF-operated aircraft, as global supply chain disruptions over the past two years have led to significant revenue losses and flight schedule cancellations in European regional traffic.