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Lufthansa Technik says forecasting component failure probabilities helps it reduce unnecessary removals.
MROs are increasingly incorporating sustainability initiatives into component repair processes. However, balancing environmental goals with the traditional priorities of safety, cost and turnaround time may require short-term trade-offs while aiming for the long-term benefits.
Sustainability has evolved from a buzzword into a strategic priority. Most MRO providers now adopt structured approaches to embed greener practices into component services, particularly in areas that generate significant waste.
FL Technics’ approach to component repair sustainability has evolved considerably, Chief Production Officer Veslav Blazevic says. The company prioritizes repair and overhaul over replacement, reducing material waste and the environmental impact of manufacturing new components.
“We’ve invested in advanced repair technologies, including nondestructive testing, which allows earlier defect detection and thus minimizes the scale and complexity of repairs,” Blazevic says. FL Technics also reuses components deemed beyond economic repair for staff training and technique development.
Furthermore, Blazevic reports that FL Technics is improving chemical inventory practices by predicting usage patterns to reduce overstocking and prevent expiration-related waste. These efforts are expected to lessen the environmental footprint, enhance operational performance and deliver long-term value to customers and the industry.
At Lufthansa Technik, sustainability efforts in component MRO are guided by three key pillars: energy efficiency, emission reduction and sustainable production practices with active initiatives that reduce emissions, minimize chemical use and cut waste generation.
“Facility upgrades are another area of focus,” says Dania Dawood, senior manager for strategy at Lufthansa Technik. Dawood highlights the company’s investment in initiatives such as solar panel installation and improvements in heating and cooling efficiency to reduce its overall carbon footprint. “On the product side, we are developing a carbon footprint framework to help customers understand the environmental impact of individually repaired components,” she says.
GA Telesis says it has embedded sustainability into its component repair strategy for the long term. Beyond the inherent environmental benefits of life-cycle extension, the company says it has redefined repair practices to drive circularity, emission reduction and industry-wide transformation with measurable results—such as a 23.52% reduction in greenhouse gas emissions in December compared with March 2024 and use of a 29.4% sustainable aviation fuel blend for aircraft engine testing in 2024.
A BALANCING ACT
Pastor Lopez, president of GA Telesis’ MRO group, says balancing the traditional aftermarket pillars—safety, cost and turnaround time—with increasing sustainability demands is both a challenge and an opportunity.
“At its core, safety will always remain the nonnegotiable foundation of any MRO operation,” Lopez says. “What’s changed is how we meet that standard while also minimizing environmental impact and meeting cost and time pressures.”
GA Telesis is taking a digital approach to the decision-making process. To that end, the company has implemented advanced planning tools and data analytics to optimize maintenance schedules. Lopez says this minimizes downtime and surplus part replacements, contributing to lower waste and carbon emissions while upholding safety standards and managing costs for operators.
“We’re shifting toward using environmentally friendly chemicals, investing in energy-efficient equipment and adopting repair-over-replace philosophies where feasible,” Lopez says. He further emphasizes that while some greener materials or methods may carry higher up-front costs, they often pay off in life-cycle savings and regulatory compliance. For example, at its landing gear maintenance base in Miami, GA Telesis is slowly replacing chromium coating with high-velocity oxygen fuel, which produces less waste due to the absence of toxic chemicals and the lower ecological footprint of the process.
Lufthansa Technik is also minimizing waste by prioritizing repair over replacement wherever possible. By extending the life of components and reducing reliance on consumable parts, “we not only conserve resources but also lessen the burden on the global supply chain,” Dawood says.
Lufthansa Technik views sustainability not as a priority that competes with cost and turnaround time, but as one that can be aligned with operational goals. For example, the company is working to reduce the carbon dioxide footprint of components moving through its network. Dawood explains that these improvements support environmental targets and contribute to cost efficiency and faster turnaround by streamlining logistics and repair processes.
“We believe that wherever safety, cost and sustainability can be harmonized, they should not be compromised,” she says. “Tools like predictive repair scheduling and route standardization enable us to reduce waste and delays while improving service reliability.”
“Many of our sustainability initiatives actually enhance—rather than hinder—core MRO performance,” Fokker Services Group Chief Financial Officer Niels Westpalm van Hoorn explains. For example, he says investing in energy efficiency, waste reduction and digital process improvements often leads to leaner, faster and more cost-effective operations. “Similarly, our focus on component repair and reuse not only reduces environmental impact but also offers a more economical solution for our customers—especially in light of the sharp rise in OEM new material prices,” he adds.
Fokker Services’ circularity and waste reduction efforts center on initiatives such as aircraft parts reuse, material recovery and responsible disposal to reduce waste and extend component life cycles.
JUGGLING POTENTIAL TRADE-OFFS
There is broad agreement that sustainability must be embedded into MRO operations without compromising safety or disrupting the tight turnaround schedules critical to airline performance. To achieve this, FL Technics says it is continually refining its workflows through digitization, Lean methodologies and predictive planning to integrate environmentally responsible practices while upholding operational efficiency and quality.
“There are, however, occasional trade-offs,” Blazevic notes. A more sustainable repair method may involve longer curing times or specialized materials, potentially delaying turnaround or raising initial costs. “In such cases, we conduct thorough assessments, weighing safety, life-cycle environmental impact, cost and operational considerations,” he says.
Some sustainable practices, such as aerodynamically flush repairs, may require more time and resources but contribute to long-term fuel savings. Conversely, faster curing methods can demand higher energy input. FL Technics says it carefully evaluates these factors to balance efficiency and environmental impact. “Our aim is to deliver repair solutions that meet OEMs’ standards while also supporting long-term environmental goals,” Blazevic says.
Lopez from GA Telesis argues that sustainability in MRO cannot be achieved in isolation and requires deep collaboration across the value chain. He says shared objectives can enable collective anticipation of supply chain disruptions, optimization of inventory strategies and co-development of greener alternatives, such as recyclable materials, bio-based lubricants or lower-emission repair methods.
Lopez says such collaboration is crucial in managing turnaround times. “In the past, supply shortages or lack of repair data might have forced a sustainability-versus-efficiency trade-off,” he says. The aftermarket can avoid delays without compromising sustainability by partnering with OEMs to access repair specifications, and with suppliers to source reclaimed or sustainably certified parts, he adds.
Sustainability efforts may slightly increase costs or extend turnaround times in some cases—for example, routing components to a specialized facility for environmentally friendly processing. “In those cases, we weigh the long-term benefits, including brand value, employee engagement and alignment with customer environmental, social and governance priorities,” Lopez says.
DIGITAL TO THE RESCUE
The aftermarket is increasingly adopting digital technologies, such as predictive maintenance, artificial intelligence (AI) and data analytics to drive more sustainable outcomes in component repair.
Fokker Services has developed digital-twin technology at its sites that can virtually replicate workstations and processes, visualize key performance indicators in real time and proactively detect inefficiencies.
Digital technologies also play a key role in advancing Fokker Services’ sustainability objectives by enabling more accurate forecasting of future used serviceable material demand based on operational planning. The company says this proactive sourcing approach supports greater material reuse while ensuring high delivery performance.
“Looking ahead, we see strong potential in AI and historical data to enhance diagnostics, improve fault isolation and support smarter repair decisions,” Westpalm van Hoorn says.
Meanwhile, Lufthansa Technik cites its Aviatar platform as an exemplary use of advanced data analytics and predictive maintenance algorithms to create a more efficient and sustainable repair network. “It forecasts component failure probabilities, enabling us to plan maintenance more effectively and reduce unnecessary removals,” Dawood says.
She also highlights a dynamic line replaceable unit planning system that uses AI to anticipate future repair events. This capability streamlines the movement of pooled components across the network, curtails excess material usage and enhances overall planning precision.
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