Air India Unveils First Retrofitted Boeing 787-8, 25 More to Undergo Upgrade

Air India on Sunday unveiled its first retrofitted legacy Boeing 787-8 aircraft, marking a major milestone in the airline’s ongoing fleet modernisation programme under the Tata Group. The twin-aisle aircraft, registered VT-ANT, is the first of 26 B787-8 planes slated for a comprehensive cabin overhaul.Originally inducted into service in 2012, the aircraft underwent an extensive nose-to-tail refurbishment as part of a broader transformation initiative launched after Tata Group’s takeover of the airline in 2022. The retrofit program began in 2025 as it faced delays of nearly one and a half years due to post-pandemic global supply chain constraints. The upgraded aircraft has now arrived in Delhi and is expected to commence operations in the coming

days.The refurbishment work was carried out at Boeing’s Modification Center in Victorville, California. The aircraft was subsequently repainted in Air India’s new livery at an FAA-certified facility in San Bernardino, California.As part of the retrofit, the aircraft was reconfigured from a two-class layout into a modern three-class configuration, bringing it in line with Air India’s latest widebody product standards, similar to the airline’s newly inducted Boeing 787-9 aircraft.

The upgrade process took approximately 12,825 manhours over 45 days. Teams stripped out the old interiors and installed new seats across all cabins, fitted new carpets and wall laminates, overhauled galleys and lavatories, and introduced a state-of-the-art inflight entertainment (IFE) system. The refurbishment required 475 metres of seat fabric, 167 metres of synthetic leather, 169 metres of carpet, and 646 litres of paint.The aircraft exterior also received a complete makeover. A 20-member team spent more than 5,700 hours across 18 days removing the old livery and applying the airline’s new branding.The revamped cabin now features 20 private Business Class suites in a 1-2-1 configuration with sliding doors, direct aisle access, and fully flat beds. Premium Economy comprises 25 seats in a 2-3-2 layout with enhanced recline and leg support, while Economy Class includes 205 ergonomically designed seats in a 3-3-3 configuration. All cabins are equipped with 4K QLED HDR touchscreens and fast-charging ports.Additional enhancements include upgraded lavatories, refurbished overhead bins, a new Cabin Service System, and an updated crew interface panel.

Campbell Wilson, Chief Executive Officer & Managing Director, Air India, said: “This is a yet another proud milestone in our transformation journey as we welcome this transformed legacy B787 aircraft as a shining beacon of the new Air India. The retrofit of our first widebody aircraft is a visible symbol of the momentum behind Air India’s transformation. With 25 other 787s undergoing this comprehensive refresh, we are rapidly modernising the backbone of our long‑haul fleet and raising the bar for customers flying between India and the world."The airline plans to complete the B787 retrofit program by 2027 as part of a US$400 million investment aimed at modernising its legacy fleet. Once completed, the upgraded aircraft are expected to operate more than 300 weekly flights to destinations across the United Kingdom, Europe, and Australia.Following the B787 upgrades, Air India will also retrofit 13 of its legacy B777-300ER aircraft as it continues its push to enhance passenger comfort and strengthen its position as a premium global carrier.