
Fleet-wide use of thinner paint layers: TAP Air Portugal is switching aircraft coatings
Following a trial phase, Portuguese airline TAP Air Portugal is introducing a new coating process for its aircraft fleet. After testing on two Airbus A320 aircraft, the airline is switching to the "Aerobase UPD" paint system from manufacturer AkzoNobel Aerospace Coatings. The process reduces the primer thickness by 36 percent and, depending on the model, lowers the aircraft's weight by up to 26 kilograms. The aim of this measure is to increase operational efficiency by reducing fuel consumption in daily flight operations. During practical tests on an Airbus A320, the airline recorded a weight saving of 24 kilograms. With a complete fleet conversion, the company expects a reduction in annual fuel consumption of approximately 428,5 tons. According to the company, this corresponds to a reduction in variable operating costs of more than €500.000 per year. The coating system maintains the resistance to external influences and weather conditions required for commercial scheduled service. Besides the reduced weight, the process changes the workflows in maintenance facilities. Since the primer is applied in a single step instead of the previously standard two coats, an intermediate drying phase is eliminated. This shortens the aircraft's time in the paint shops and simplifies the work processes for technical personnel. The modified formula also exhibits greater resistance to paint runs, resulting in a more uniform coating thickness on the aircraft's outer skin. Aviation experts point out that weight savings in the aircraft structure are one of many ways to reduce ongoing operating costs. While the savings per individual aircraft are relatively small, the cumulative effect is significant.








