Air India on Sunday unveiled its first retrofitted Boeing 787-8 aircraft, marking the rollout of a $400 million programme to upgrade its legacy widebody fleet and sharpen its competitive edge on long-haul routes.

The aircraft (VT-ANT), the first of 26 Dreamliners slated for refurbishment, has undergone a comprehensive nose-to-tail upgrade, including new cabin interiors and the airline’s refreshed livery. The retrofit was executed in the United States, underscoring the scale and global coordination involved in the effort.

Premium push anchored in new three-class cabin

At the heart of the overhaul is a shift to a three-class cabin configuration, replacing the earlier two-class layout. The redesigned Business Class features 20 private suites with sliding doors and fully flat beds, positioning Air India more competitively in the premium long-haul segment.

The introduction of Premium Economy — with 25 seats offering greater comfort and space — reflects changing traveller preferences, while the 205-seat Economy cabin has been upgraded with improved ergonomics and larger inflight entertainment screens.

The aircraft also features refreshed interiors, upgraded galleys and lavatories, and a new-generation inflight entertainment system, bringing it in line with the airline’s newer widebody standards.

$400 million retrofit programme gains momentum

The Dreamliner refurbishment is part of a broader $400 million investment by Air India to modernise its legacy fleet. In total, 25 additional Boeing 787 aircraft are set to undergo similar upgrades over the next year, with two already in the pipeline.

The scale of the first retrofit highlights the complexity of the programme. The upgrade required over 12,800 manhours across 45 days, involving a complete strip-down and rebuild of cabin interiors, alongside extensive testing of new systems and components. The aircraft was also repainted in the new livery after more than 5,700 hours of exterior work.

Once completed by 2027, the retrofit programme is expected to significantly upgrade passenger experience on over 300 weekly flights across key international routes, including Europe, the UK and Australia.

The initiative is part of Air India’s wider transformation strategy under the Tata Group, which includes fleet renewal, product upgrades and service enhancements aimed at repositioning the airline as a premium global carrier.