AkzoNobel Aerospace Coating Cuts Weight for TAP Air Portugal Fleet

AkzoNobel’s Aerospace Coatings business and TAP Air Portugal have successfully completed operational trials of lighter aircraft basecoat technology which can reduce coating weight by up to 26kg per aircraft.

Based on projected fleet-wide implementation, the lightweight Aerobase UPD formulation is expected to contribute to annual fuel savings of approximately 428.5 tons¹. This would result in annual cost savings of more than half a million euros¹ and an estimated reduction of around 1,353 tons of CO₂eq emissions¹.

The trials demonstrated that the innovative Aerobase UPD system can reduce total basecoat film thickness by 36% compared with the previous two-coat formulation, while maintaining the durability, appearance and finish quality standards required for commercial aviation operations.

Photo: AkzoNobel

“We continuously evaluate opportunities to improve operational efficiency and reduce environmental impact across our operations,” explains João Carvalho, Structures Engineer at TAP Air Portugal.

“The results achieved through this collaboration with AkzoNobel Aerospace Coatings demonstrate how relatively small weight reductions, when applied consistently across aircraft fleets, could contribute to meaningful long-term fuel and emissions savings, while also supporting operational efficiency.”

Patrick Bourguignon, Director of AkzoNobel’s Automotive and Specialty Coatings business, adds: “By reducing total film build and simplifying the application process, Aerobase UPD helps operators lower aircraft weight, improve paint shop productivity and maintain the high quality finish standards required across commercial aviation fleets.

“This program with TAP Air Portugal clearly demonstrates how incremental innovations in coating technology can deliver measurable operational benefits and emissions savings for airlines.”

The Aerobase UPD coating enables the required hiding power and finish quality to be achieved through a single basecoat application cycle, eliminating the need for a second full basecoat layer and associated flash-off stages. The enhanced formulation also delivers approximately 40% greater sag resistance compared with the traditional two-layer system.

Aerobase UPD is certified to AMS3095 standards for global mixed-fleet MRO operations and integrates with the upgraded Aerobase activator and existing Aerobase hardeners, enabling straightforward implementation within existing paint shop processes.

Learn more about AkzoNobel’s Aerospace Coatings business: https://aerospace.akzonobel.com/en

¹ Estimates based on full-fleet application of TAP Air Portugal with Aerobase UPD system, current fuel prices and DEFRA 2026 aviation fuel emission conversion factors. For more details, see: ghg-conversion-factors-2026-full-set