Kerry Pianoforte, Editor05.16.24
CW: Has the airline industry recovered from the pandemic? Did you see an increased demand for aerospace coatings in 2023?
AkzoNobel: All of the indicators suggest that the airlines have indeed recovered. World passenger numbers were close to pre-pandemic levels and ended the year just 3% off the 2019 peak. Passenger revenues have also recovered. The resilience of the airlines is quite remarkable, but perhaps reflects our thirst for travel. Passenger numbers fell by 60% during COVID and even when demand began to return in 2022, traffic was still down more than a quarter (27%) on pre-pandemic levels. Seen in that context, airlines are now pointing with greater confidence to the future and that is certainly reflected in an increased demand for our aerospace coatings.
Mankiewicz: 2023 was a fantastic year for the aviation industry. And not just in comparison to previous years, which were still affected by the pandemic and its aftermath. According to Flightradar 24, more than 250,000 aircraft were in the air at the same time on July 6, 2023 - more than ever before. And more than 3,800 new orders are a new global annual record. Deliveries are also at a very high level, with nearly 1,300 aircraft. In short, the industry has recovered very well and is in a solid position. For Mankiewicz, 2022 was already a year above the pre-pandemic level, and this trend has continued very positively in 2023, also driven by product innovation and performance.
PPG: The aviation market is having a strong recovery following the COVID pandemic. For the most part, the aerospace coatings industry has recovered and things are back to normal. While there are still some minor supply chain issues and costs are higher, we saw our volumes return to pre-pandemic levels in 2023.
CW: What factors are driving growth for aerospace coatings?
Mankiewicz: The very positive market figures for new orders and deliveries keep the skies crowded and create an increasing rush for maintenance and repairs. And it is precisely this challenge that is also one of the most positive drivers for the aviation coatings industry.
This is because the capacity shortage in the maintenance and repair (MRO) segment can be countered from two directions with suitable coating solutions. The first is the longevity and durability of coating systems, as long-lasting coating systems such as the ALEXIT BaseCoat/ClearCoat system reduce maintenance costs and increase the lifecycle of surfaces.
The second direction is the lean and robust application properties. Innovative, process-optimized coatings help to reduce the time required to repair an existing or create a new livery design. Fast drying times and high coverage with accompanying single-layer application are the key factors here. Aircraft can return to flight operations in a shorter time, and at the same time, the throughput of aircraft at the MRO increases.
When it comes to cabin interior coatings there is another aspect that has a positive impact and that is the diversity and flexibility of paint systems. When building and maintaining aircraft, you are confronted with many different substrates, some with complex component symmetry.
In addition, there are functional and design requirements to ensure the safety and visual well-being of passengers. Coatings, with their wide range of looks and performance properties, are very efficient in this respect. Particularly in the interior, FST requirements can be met, and many different designs can be created at the same time. This allows the creation of various effects ranging from metal to frosted glass without the weight of,
for example, metal.
Thanks to the good spot repairability, smaller surfaces can be repaired selectively without having to redo an entire component, as would be the case with other surface materials. Mankiewicz has an extensive portfolio of effect coatings that give the airline or manufacturer a free choice of combination in terms of color tone, effect, gloss level, and even tactile effects while offering a wide range of technical performance characteristics.
PPG: All OEM order books are up and backlogged for 10+ years. Challenges and opportunities that fuel growth will be adopting more automation for the paint application processes for the OEM, including AEROCRON™ electrocoat primer and robotic paint application. Also, the inclusion of chrome-free technologies meeting the same performance as chrome products.
CW: What high performance characteristics do your customers demand (weight reductions, durability, etc.)?
AkzoNobel: Commercial airlines are subjected to some of the harshest conditions imaginable, including extremes of heat, cold, rain, lightning, and pressure, as well as general ‘wear and tear’ and assault from chemicals and pollutants in the air. Creating a single coating that protects everything is a challenge, but a coating system comprised of multiple components, each with a specific function, is possible, and can be very effective.
Performance is primarily driven by the polymer network – the resins which keep the pigments together, providing overall cohesion of the paint film and adhesion to the substrate. They also give the coating its performance and durability. Formulating a coating that delivers at 40,000 feet while approaching the speed of sound is achieved through our in-house polymer synthesis capability to design and manufacture custom resins.
We create a layer of multiple coatings, each with specific capabilities, that together act as multiple protective layers below the visible paint. The hardest working, toughest, and most technically advanced coatings are the ones that will never been seen by anyone but the applicator.
It’s also important to note that the coatings you can see – the splendid liveries and one-off ‘specials’ to celebrate a particular anniversary or event – comprise only a small part of the overall aerospace coatings story, where the customer demand is as much about color and aesthetic appeal as it is durability. Structural coatings on the parts you cannot see but that protect those parts from corrosion etc. are perhaps the true unsung heroes of the aerospace coatings industry. Then the customer demand is focused solely
on protection.
Mankiewicz: Weight reduction is an ongoing industry requirement. There is a direct correlation between weight and fuel consumption, which is the biggest cost driver for airlines. When looking at the 250,000 aircraft in the sky in one day in summer 2023, every kilogram of weight the industry can save counts for sustainability reasons. On the one hand, it helps if you contribute to this with weight-saving coating solutions. On the other hand, the optics of heavier materials can be reproduced, which, in the original material, would add much more weight to the aircraft.
A fundamental requirement of the paint shops of OEMs and MROs alike is a robust processing. Speed without sacrificing quality is key in all areas of aircraft painting. That is why Mankiewicz places great emphasis on efficient and robust customer processes. A good product is not enough. Lean processes and also training are high on Mankiewicz’s agenda.
Composites continue to be an exciting material field in the aviation industry. This highly stable and flexible material is ideally suited for sustainable aircraft construction.
To provide the economic character of composites with a perfect coating finish, a specific preparation with dedicated surface correctors is required before the final coating layers are applied. This is because, unlike metallic components, composites often have an inherently uneven surface.
The importance of fillers is particularly evident in the aviation industry. If aircraft parts were painted without special preparatory work, these irregularities would be magnified, especially with high-gloss paint systems that follow. This would result in an uneven surface and would not have the desired high gloss wet look effect.
From pinholes to large-sized defects, the suitable filler choice depends on the defect. Combining the different Mankiewicz filler solutions can save even composite parts with very poor surface quality. This reduces scrap part rate and makes the production more sustainable. Our customers appreciate that Mankiewicz offers them a choice of qualified products, depending on how they want to apply and the type of defects they want to repair. All have excellent filling properties with very low shrinkage and are applicator friendly.
PPG: At PPG, our aerospace coatings focus on sustainability, enabling our customers to be more efficient and performance – light weight and durable coatings, coupled with survivability for military coatings.
With the ever-changing regulatory landscape, this has become a challenge from a formulation standpoint as some of the traditionally used raw materials (solvents, additives, corrosion inhibitors, etc.) can no longer be used or will not be allowed in the near future. It can be daunting to find alternative materials that give the same or improved performance while still upholding regulatory compliance.
CW: How often does a plane need to be repainted/how often do companies change the livery?
AkzoNobel: Some aircraft can last for up to ten years or even more before they need to be repainted. That’s largely because of the way external coatings have evolved in the last decade from single stage to basecoat/clearcoat systems. Typically, however, aircraft are taken out of service for maintenance every six or seven years without really knowing if a repaint is needed.
That was the driver behind our launch last year of AeroFleet Coatings Management, a new digital, data-driven service that helps airlines and other large operators to tailor and optimise the coatings’ replacement and maintenance schedule for individual aircraft within an airline fleet. It captures the data from both manual inspections and drone-operated inspections, creating a database of every aircraft in a fleet.
The history includes details of the coatings used (e.g. single stage or basecoat/clearcoat coatings) along with flight path data (e.g. weather conditions etc.) which affect the integrity/longevity of the coating applied.
By analyzing the captured information (e.g dry film thickness, color variation, gloss and general appearance), and mapping it over time, a more accurate maintenance and repaint schedule can be calculated and it becomes easier and more accurate to determine when an aircraft needs to be repainted, rather than simply using time or flight hours.
Schedules can be created that balance the practical performance of a coating and where the aircraft in a fleet are being operated (i.e. the different flight paths, distances, altitudes, environment etc.) against the aesthetic/marketing (i.e. branding) and business needs of the airline.
Mankiewicz: For reasons of sustainability and economy, airlines are keen to have to repaint as little as possible to achieve maximum efficiency in both areas. A desirable exception is when an aircraft is fitted with a special livery for a particular occasion or event or when an airline decides to re-brand.
Of course, there always comes a point when an airline decides to repaint an aircraft because the external appearance of the aircraft is the first calling card when passengers see it. A flawless appearance also underlines the passengers’ sense of security. With conventional systems, this time often comes already after five years.
However, with the ALEXIT BaseCoat/ClearCoat system, Mankiewicz has established a coating solution that has proven that this renewal cycle can be extended to up to 13 years - while maintaining good gloss and durability.
The BaseCoat/ClearCoat system is also a good choice for complex designs with various colors for the special liveries mentioned above. Here, short drying times and the wild spraying method offer enormous time savings. In addition, customers can draw on the expertise of the Mankiewicz design department and the global Colorimetry team when selecting and developing colors.
This hand-in-hand approach between customer and paint manufacturer is traditionally part of the coating experts’ philosophy. Mankiewicz believes that perfect finishes are always the result of a cooperative partnership.
A pain point for airlines is often the wings, which, unlike the fuselage, are mostly painted with two different topcoats. Traditionally, different topcoats are used on the upper and lower wing boxes, making coating the wings time-consuming with all the masking and drying.
This time-consuming work often has to be done before the aircraft’s regular maintenance cycle because the wings look aged much sooner than the rest of the aircraft, as the wings move a lot, and hydraulic and de-icing fluids and kerosene also cause chemical stress.
This is where Mankiewicz launched a 2-in-1 product with its ALEXIT WingFlex as a solution to the requirements of this special area. The unique feature is that the topcoat can be applied to both wing sides and is also repairable. This shortens the painting process, and the performance of the surface is impressive in terms of durability and optical properties.
PPG: The airlines are typically repainting planes on a six-to-eight-year cycle, up from four years. This is due to the basecoat/clearcoat (BCCC) having a longer service life and retaining the color and gloss much better. Full livery changes typically take place every 15 to 20 years or when another airline is acquired by someone else. We are seeing more special liveries now as airlines paint a plane or two to coincide with a special global event.
AkzoNobel: All of the indicators suggest that the airlines have indeed recovered. World passenger numbers were close to pre-pandemic levels and ended the year just 3% off the 2019 peak. Passenger revenues have also recovered. The resilience of the airlines is quite remarkable, but perhaps reflects our thirst for travel. Passenger numbers fell by 60% during COVID and even when demand began to return in 2022, traffic was still down more than a quarter (27%) on pre-pandemic levels. Seen in that context, airlines are now pointing with greater confidence to the future and that is certainly reflected in an increased demand for our aerospace coatings.
Mankiewicz: 2023 was a fantastic year for the aviation industry. And not just in comparison to previous years, which were still affected by the pandemic and its aftermath. According to Flightradar 24, more than 250,000 aircraft were in the air at the same time on July 6, 2023 - more than ever before. And more than 3,800 new orders are a new global annual record. Deliveries are also at a very high level, with nearly 1,300 aircraft. In short, the industry has recovered very well and is in a solid position. For Mankiewicz, 2022 was already a year above the pre-pandemic level, and this trend has continued very positively in 2023, also driven by product innovation and performance.
PPG: The aviation market is having a strong recovery following the COVID pandemic. For the most part, the aerospace coatings industry has recovered and things are back to normal. While there are still some minor supply chain issues and costs are higher, we saw our volumes return to pre-pandemic levels in 2023.
CW: What factors are driving growth for aerospace coatings?
Mankiewicz: The very positive market figures for new orders and deliveries keep the skies crowded and create an increasing rush for maintenance and repairs. And it is precisely this challenge that is also one of the most positive drivers for the aviation coatings industry.
This is because the capacity shortage in the maintenance and repair (MRO) segment can be countered from two directions with suitable coating solutions. The first is the longevity and durability of coating systems, as long-lasting coating systems such as the ALEXIT BaseCoat/ClearCoat system reduce maintenance costs and increase the lifecycle of surfaces.
The second direction is the lean and robust application properties. Innovative, process-optimized coatings help to reduce the time required to repair an existing or create a new livery design. Fast drying times and high coverage with accompanying single-layer application are the key factors here. Aircraft can return to flight operations in a shorter time, and at the same time, the throughput of aircraft at the MRO increases.
When it comes to cabin interior coatings there is another aspect that has a positive impact and that is the diversity and flexibility of paint systems. When building and maintaining aircraft, you are confronted with many different substrates, some with complex component symmetry.
In addition, there are functional and design requirements to ensure the safety and visual well-being of passengers. Coatings, with their wide range of looks and performance properties, are very efficient in this respect. Particularly in the interior, FST requirements can be met, and many different designs can be created at the same time. This allows the creation of various effects ranging from metal to frosted glass without the weight of,
for example, metal.
Thanks to the good spot repairability, smaller surfaces can be repaired selectively without having to redo an entire component, as would be the case with other surface materials. Mankiewicz has an extensive portfolio of effect coatings that give the airline or manufacturer a free choice of combination in terms of color tone, effect, gloss level, and even tactile effects while offering a wide range of technical performance characteristics.
PPG: All OEM order books are up and backlogged for 10+ years. Challenges and opportunities that fuel growth will be adopting more automation for the paint application processes for the OEM, including AEROCRON™ electrocoat primer and robotic paint application. Also, the inclusion of chrome-free technologies meeting the same performance as chrome products.
CW: What high performance characteristics do your customers demand (weight reductions, durability, etc.)?
AkzoNobel: Commercial airlines are subjected to some of the harshest conditions imaginable, including extremes of heat, cold, rain, lightning, and pressure, as well as general ‘wear and tear’ and assault from chemicals and pollutants in the air. Creating a single coating that protects everything is a challenge, but a coating system comprised of multiple components, each with a specific function, is possible, and can be very effective.
Performance is primarily driven by the polymer network – the resins which keep the pigments together, providing overall cohesion of the paint film and adhesion to the substrate. They also give the coating its performance and durability. Formulating a coating that delivers at 40,000 feet while approaching the speed of sound is achieved through our in-house polymer synthesis capability to design and manufacture custom resins.
We create a layer of multiple coatings, each with specific capabilities, that together act as multiple protective layers below the visible paint. The hardest working, toughest, and most technically advanced coatings are the ones that will never been seen by anyone but the applicator.
It’s also important to note that the coatings you can see – the splendid liveries and one-off ‘specials’ to celebrate a particular anniversary or event – comprise only a small part of the overall aerospace coatings story, where the customer demand is as much about color and aesthetic appeal as it is durability. Structural coatings on the parts you cannot see but that protect those parts from corrosion etc. are perhaps the true unsung heroes of the aerospace coatings industry. Then the customer demand is focused solely
on protection.
Mankiewicz: Weight reduction is an ongoing industry requirement. There is a direct correlation between weight and fuel consumption, which is the biggest cost driver for airlines. When looking at the 250,000 aircraft in the sky in one day in summer 2023, every kilogram of weight the industry can save counts for sustainability reasons. On the one hand, it helps if you contribute to this with weight-saving coating solutions. On the other hand, the optics of heavier materials can be reproduced, which, in the original material, would add much more weight to the aircraft.
A fundamental requirement of the paint shops of OEMs and MROs alike is a robust processing. Speed without sacrificing quality is key in all areas of aircraft painting. That is why Mankiewicz places great emphasis on efficient and robust customer processes. A good product is not enough. Lean processes and also training are high on Mankiewicz’s agenda.
Composites continue to be an exciting material field in the aviation industry. This highly stable and flexible material is ideally suited for sustainable aircraft construction.
To provide the economic character of composites with a perfect coating finish, a specific preparation with dedicated surface correctors is required before the final coating layers are applied. This is because, unlike metallic components, composites often have an inherently uneven surface.
The importance of fillers is particularly evident in the aviation industry. If aircraft parts were painted without special preparatory work, these irregularities would be magnified, especially with high-gloss paint systems that follow. This would result in an uneven surface and would not have the desired high gloss wet look effect.
From pinholes to large-sized defects, the suitable filler choice depends on the defect. Combining the different Mankiewicz filler solutions can save even composite parts with very poor surface quality. This reduces scrap part rate and makes the production more sustainable. Our customers appreciate that Mankiewicz offers them a choice of qualified products, depending on how they want to apply and the type of defects they want to repair. All have excellent filling properties with very low shrinkage and are applicator friendly.
PPG: At PPG, our aerospace coatings focus on sustainability, enabling our customers to be more efficient and performance – light weight and durable coatings, coupled with survivability for military coatings.
With the ever-changing regulatory landscape, this has become a challenge from a formulation standpoint as some of the traditionally used raw materials (solvents, additives, corrosion inhibitors, etc.) can no longer be used or will not be allowed in the near future. It can be daunting to find alternative materials that give the same or improved performance while still upholding regulatory compliance.
CW: How often does a plane need to be repainted/how often do companies change the livery?
AkzoNobel: Some aircraft can last for up to ten years or even more before they need to be repainted. That’s largely because of the way external coatings have evolved in the last decade from single stage to basecoat/clearcoat systems. Typically, however, aircraft are taken out of service for maintenance every six or seven years without really knowing if a repaint is needed.
That was the driver behind our launch last year of AeroFleet Coatings Management, a new digital, data-driven service that helps airlines and other large operators to tailor and optimise the coatings’ replacement and maintenance schedule for individual aircraft within an airline fleet. It captures the data from both manual inspections and drone-operated inspections, creating a database of every aircraft in a fleet.
The history includes details of the coatings used (e.g. single stage or basecoat/clearcoat coatings) along with flight path data (e.g. weather conditions etc.) which affect the integrity/longevity of the coating applied.
By analyzing the captured information (e.g dry film thickness, color variation, gloss and general appearance), and mapping it over time, a more accurate maintenance and repaint schedule can be calculated and it becomes easier and more accurate to determine when an aircraft needs to be repainted, rather than simply using time or flight hours.
Schedules can be created that balance the practical performance of a coating and where the aircraft in a fleet are being operated (i.e. the different flight paths, distances, altitudes, environment etc.) against the aesthetic/marketing (i.e. branding) and business needs of the airline.
Mankiewicz: For reasons of sustainability and economy, airlines are keen to have to repaint as little as possible to achieve maximum efficiency in both areas. A desirable exception is when an aircraft is fitted with a special livery for a particular occasion or event or when an airline decides to re-brand.
Of course, there always comes a point when an airline decides to repaint an aircraft because the external appearance of the aircraft is the first calling card when passengers see it. A flawless appearance also underlines the passengers’ sense of security. With conventional systems, this time often comes already after five years.
However, with the ALEXIT BaseCoat/ClearCoat system, Mankiewicz has established a coating solution that has proven that this renewal cycle can be extended to up to 13 years - while maintaining good gloss and durability.
The BaseCoat/ClearCoat system is also a good choice for complex designs with various colors for the special liveries mentioned above. Here, short drying times and the wild spraying method offer enormous time savings. In addition, customers can draw on the expertise of the Mankiewicz design department and the global Colorimetry team when selecting and developing colors.
This hand-in-hand approach between customer and paint manufacturer is traditionally part of the coating experts’ philosophy. Mankiewicz believes that perfect finishes are always the result of a cooperative partnership.
A pain point for airlines is often the wings, which, unlike the fuselage, are mostly painted with two different topcoats. Traditionally, different topcoats are used on the upper and lower wing boxes, making coating the wings time-consuming with all the masking and drying.
This time-consuming work often has to be done before the aircraft’s regular maintenance cycle because the wings look aged much sooner than the rest of the aircraft, as the wings move a lot, and hydraulic and de-icing fluids and kerosene also cause chemical stress.
This is where Mankiewicz launched a 2-in-1 product with its ALEXIT WingFlex as a solution to the requirements of this special area. The unique feature is that the topcoat can be applied to both wing sides and is also repairable. This shortens the painting process, and the performance of the surface is impressive in terms of durability and optical properties.
PPG: The airlines are typically repainting planes on a six-to-eight-year cycle, up from four years. This is due to the basecoat/clearcoat (BCCC) having a longer service life and retaining the color and gloss much better. Full livery changes typically take place every 15 to 20 years or when another airline is acquired by someone else. We are seeing more special liveries now as airlines paint a plane or two to coincide with a special global event.
