Emirates is the only airline in the world to have made the Airbus SE jumbo A380 jet an integral part of its fleet. Dubai Airlines still has more than 100 double-deckers in its fleet, while rivals have given up or only fly a few. Airbus also halted production in 2019, after a little over ten years of low sales.
Emirates is refurbishing its aircraft with a $2 billion investment to extend their lifespan until the early 2040s.In a huge hangar near Dubai’s main airport, two A380s underwent a massive refurbishment program last week. The planes were gutted and retrofitted to include everything from new berths or fresh stairs.
Emirates replaced the wood paneling and gold trims with lighter colors, new carpeting, mood lighting, and depictions of local nature themes.The popular bar in business class, where passengers can enjoy a whiskey and mingle with other passengers during the flight, will remain. Phoenix Project, the name given to the cabin upgrade alone, accounts for about half of the investment.
The upgrade for Emirates is not just a simple touch-up, as it happens with most airline fleets. The A380 is a symbol of the ambitions of the world’s biggest international airline to connect as many people via its Dubai hub. The A350-900, due next year, is either too small for the job or, like the Boeing Co. 7777X, they are years behind schedule. This means Emirates must keep the A380s longer than originally planned.
The size of these planes – an A380 has about 550 seats spread over two decks – means that the overhaul generates a large amount of recyclable materials. Emirates claims that one aircraft sheds over 250 kilograms (595 lbs) of leather seat and 600 kilograms (or other fabric). The airline will use these materials to create a limited edition collection of shoes and belts.
The fleet is still relatively young, with an average age of 10 years. The airline originally expected the refurbishment of half its A380 fleet to take two years. The surge in travel demand has increased the need for aircraft, so Emirates is speeding up the maintenance process. Up to now, 16 aircraft have been retrofitted and are in service, while another two are being refurbished.
The majority of the upgrades were done internally, and the state owned carrier designed its operations to be mostly self-sufficient. As the A380 becomes a rarer sight in the skies over the next decade, the company has designed their operations to become largely independent.
Emirates President Tim Clark lobbied Airbus for years to keep the A380 or at least to consider new engines that would make it more efficient. Airbus finally pulled the plug on Airbus’ most prestigious plane.
Clark told the Dubai Airshow that he would keep production going for as long as possible. Clark’s efforts to maintain production were criticized by some. “I have been hammering on about it and they always send me to the looney bin but here we are,” Clark stated.
The plane has been a big hit with passengers who appreciate its spacious layout, quiet interior and imposing appearance. However, many airlines have had difficulty accommodating it. The A380, with its four engines – like the 747 jumbo that was also discontinued – consumes more fuel than two-engined models. Some of these can carry as many passengers.
A number of A380s are already in aircraft graveyards where their parts and pieces are being recycled. Fans can purchase key rings made from the aluminum skin of the A380, a tribute to the plane’s sentimental value.
Emirates’ recycled accessories tap into the same nostalgia. Along with shoes, belts, and backpacks made from A380 scraps, you’ll also find toiletry bags, suitcases on wheels, and luggage tags. They’re made by hand in the engineering facility and will be available in limited quantities next year. Laser engraving is an option.
Clark explained: “We’re cannibalizing early aircraft, storing their parts and making some into really nice bags or suitcases.” “Unless we convince them to build another.”