TAP Air Portugal adopts lightweight painting technology, cutting fuel use

TAP Air Portugal completed operational tests of a new lightweight basecoat painting system developed by AkzoNobel Aerospace Coatings. The Aerobase UPD formulation reduces coating thickness by 36%, cutting up to 26 kg of weight per aircraft. Field trials on an Airbus A320 showed a 24 kg weight reduction, and a second A320 has already been painted with the new process.

If rolled out across the entire fleet, the airline expects annual fuel savings of about 428.5 tonnes, a cost reduction of over half a million euros, and an estimated reduction of 1,353 tonnes of CO₂ emissions. The single‑cycle application also streamlines the painting workflow by eliminating a second coat, improving productivity and coating consistency.