Air India’s 100-Plane Expansion: Can It Build Fast Enough To Keep Up?

Air India is preparing for a major fleet expansion, with the group planning to induct more than 100 aircraft over the next two years. But as the airline expands, questions are emerging over whether its workforce, maintenance infrastructure and operational systems can grow quickly enough to support the larger fleet.

Air India CEO Campbell Wilson recently told employees that the group expects to add over 100 planes while also retrofitting 16 Boeing 787-8 aircraft in 2027. Air India and Air India Express together currently operate nearly 300 aircraft, making the planned expansion one of the most ambitious phases in the group’s transformation.

However, the expansion comes as Air India continues to face significant financial and operational pressures. The airline reported a ₹22,238 crore net loss in FY2025-26, more than double its previous year's loss. Higher fuel costs, geopolitical tensions, airspace restrictions, longer international routes and weaker demand in some markets have added to the challenges.

A larger fleet will also require thousands of additional employees, including pilots, cabin crew, engineers, technicians and ground staff. Maintenance capacity will be equally important, particularly as Air India operates a diverse fleet of Airbus and Boeing aircraft. The airline is expanding its engineering and maintenance infrastructure, including a major MRO facility in Bengaluru, but India's aviation sector is itself facing shortages of skilled technical personnel.

Recent events have highlighted the importance of maintaining strong safety systems. On August 4, an Air India Phuket-Delhi flight suddenly lost around 300 feet of altitude, injuring 24 people. Preliminary Airbus analysis found that the aircraft briefly lost key flight controls following simultaneous failures involving its three hydraulic systems. The root cause remains under investigation by the Aircraft Accident Investigation Bureau (AAIB), Airbus and France's BEA.

The incident should not, however, be treated as proof of a staffing or maintenance shortage. Investigators have yet to establish a definitive cause.

Meanwhile, Tewolde Gebremariam, former Ethiopian Airlines Group chief, is set to replace Wilson as Air India CEO. His task will be to turn the rebuilt airline into a more reliable and financially sustainable carrier.

Air India’s real challenge is therefore bigger than simply acquiring 100 aircraft. It must build the people, maintenance capacity, operational discipline and financial strength needed to operate a fleet of more than 400 aircraft safely and efficiently.