In a major step in its ongoing transformation journey, Air India has unveiled its first retrofitted twin-aisle Boeing 787-8 aircraft (VT-ANT), marking the completion of a comprehensive nose-to-tail cabin refresh for the first of its 26 B787 aircraft.
The aircraft underwent an extensive interior upgrade at Boeing’s modification centre in Victorville, California, before receiving the airline’s bold new livery at AeroPro’s FAA-certified paint facility in San Bernardino.
From legacy to next-gen cabin experience
The retrofit marks a complete transformation of the aircraft’s interiors, shifting from a traditional two-class layout to a modern three-class configuration. With new seating, upgraded inflight entertainment systems and redesigned cabin elements, the aircraft now aligns with Air India’s latest widebody standards, similar to its recently inducted Boeing 787-9 fleet.
The scale of the overhaul underscores the complexity involved. The first retrofit alone required nearly 12,825 manhours over 45 days, as teams stripped out legacy interiors, reconfigured cabins, installed new components and carried out rigorous testing across systems.
Precision engineering meets design overhaul
The refurbishment effort extended down to the finest detail. Hundreds of metres of fabric, leather and carpeting were used to craft the new interiors, alongside significant quantities of paint for both cabin and exterior enhancements. The aircraft’s exterior makeover itself took over 5,700 hours across 18 days, handled by a specialised team focused on delivering the airline’s refreshed visual identity.
A sharper product across all cabins
The upgraded 787-8 aircraft now offers a significantly enhanced passenger experience across all three classes.
Business Class has been reimagined with 20 private suites in a 1-2-1 configuration, featuring sliding doors, direct aisle access and fully flat beds, along with high-resolution 4K QLED screens and thoughtful design touches inspired by Indian aesthetics.
Premium Economy introduces 25 seats in a 2-3-2 layout, offering greater comfort with deeper recline, enhanced leg support and larger entertainment screens, alongside fast-charging options for personal devices.
Economy Class, with 205 seats in a 3-3-3 configuration, has been ergonomically optimised to provide improved comfort, modern touchscreen displays and convenient charging ports.
Across the aircraft, enhancements include new carpets and curtains, redesigned wall laminates, upgraded galleys and lavatories, refreshed overhead panels and the installation of a new cabin service system with an updated crew interface. The cabins are fitted with advanced seating solutions and powered by next-generation inflight entertainment technology from Thales.
Leadership view: A visible shift in transformation
Air India CEO and MD Campbell Wilson described the rollout as a defining milestone. He noted that the retrofitted aircraft represents the tangible progress of the airline’s transformation strategy, with 25 more 787-8 aircraft set to undergo similar upgrades.
$400 million bet on fleet modernisation
The retrofit programme is part of a broader $400 million investment aimed at modernising Air India’s legacy fleet. The initiative, executed in collaboration with Boeing, is designed to elevate quality, safety and consistency across the airline’s long-haul operations.
Over the next year, Air India plans to retrofit the remaining 25 B787 aircraft, with two already in progress. Once completed by 2027, the upgraded fleet is expected to enhance passenger experience across more than 300 weekly flights connecting India with key global markets including the UK, Europe and Australia.
The airline will also extend the upgrade programme to its Boeing 777-300ER fleet, further reinforcing its ambition to reposition itself as a premium global carrier.