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Vallair, a seasoned expert in aircraft maintenance, repair, and overhaul (MRO), has finalized the establishment of its state-of-the-art facility for aerostructure repair, engine teardown, and component repair in Châteauroux, France. This fully integrated facility optimizes operations, reducing both time and expenses for airlines and lessors. By consolidating these capabilities, Vallair provides a cost-effective solution for extending the lifespan of significant components that would otherwise incur high transportation costs for repair.
Vallair is currently seeing an increase in repairs for nacelles and flight control parts with customers choosing to work with their reactive team. François Biarneix, Operations Director in Châteauroux, explains why this is, “We have a short decision-making circuit at Vallair and a highly experienced technical team. Many customers come for specific aerostructure expertise, but we also encompass a lot of ad hoc work for those with aircraft undergoing C-check maintenance. Using our integrated services reduces TATs considerably. If a part such as a fan cowl needs to be repaired, we can provide an immediate quote and start processing the repair without delay.”
As Biarneix observes, “The global aerostructure repair services market is influenced by several factors, including the growth of the aviation sector and the increasing age of commercial aircraft fleets. Outsourcing aerostructure repairs can offer customers cost savings via access to specialised expertise. We are shaping our facility and our development programme to meet the challenges of the skills shortage coupled with the need for rapid turnaround times, and the complexities involved in repairing newer composite materials. To support this, we have our own Part 147 EASA approved training centre, Aircraft Academy, on-site in Châteauroux. This is focused on the next generation of technicians and engineers and delivers theoretical and practical courses across a broad range of Airbus and Boeing narrow and wide body aircraft and aligned engine types.”
The aerostructure repair services sector is integral to ensuring the safety, efficiency, and operational readiness of the global aviation fleet. Vallair’s MRO operations encompass vital tasks such as structure inspection and repair, composites inspection and repair, as well as painting for nacelles, flight controls, and cabin parts.
Looking forward, Vallair is positioned for continued expansion and innovation. The integration of digital technologies for training and repair guidance will equip their skilled technicians to adapt to emerging trends in sustainable repair materials and advancements in processes.
Biarneix highlights one of Vallair’s key MRO strengths: proximity of its aerostructures and engine shops to its expansive new maintenance facility in Châteauroux, capable of concurrently accommodating two A330 widebodies and one A320/B737 family aircraft. Furthermore, Vallair provides distinct advantages in aircraft and engine dismantling, strategically located in the heart of Europe.According to Biarneix, lessors and operators frequently look for facilities in hot and dry climates to handle this activity, but because Vallair undertakes the process inside their hangars, weather is not a factor. “Most importantly we are in the fortunate position of being able to offer a range of integrated services that are complementary to the teardown process on-site. These include cleaning, inspection, analysis, photography, packing and storage of all the dismantled parts. This saves our customers time and is very efficient.”
Similar time-saving benefits extend to Vallair’s recently enhanced engine shop, specializing in CFM56 and V2500 series engines. The range of services encompasses module disassembly and reassembly, minor repairs and inspections, borescope inspections, preservation, as well as engine, APU, and engine bay leasing. Additionally, borescope capabilities are set to expand to include Trent 700, PW 4000, CF6-80, Leap, and PW1100 engines in the near future.
“Engine teardown facilities are an integral part of the aviation industry’s ecosystem, providing a critical service in the management of aircraft engine lifecycles,” says Biarneix. “Vallair is accredited by AFRA, the Aircraft Fleet Recycling Association, this ensures that quality standards are maintained through the entire process. As the international aerospace community continues to focus on environmental issues, asset owners are looking for efficient, revenue-building and environmentally-sound methods for aircraft disposal. From parts distribution, to dismantling, through to materials recycling, Vallair is working on new strategies for management of end-of-life aircraft. With up to 15,000 aircraft due to retire in the next two decades, aircraft recycling offers a broad range of opportunities and Vallair aims to be at the forefront of this sector.”
Vallair, an aviation enterprise headquartered in Luxembourg, operates facilities in Châteauroux and Montpellier, France. Specializing in comprehensive support for mature aircraft, engines, and key components, Vallair comprises seven interconnected business units built upon a foundation of engineering expertise: trading and leasing, cargo conversions, aircraft maintenance, repair, and overhaul (MRO), engine services, aerostructures and painting, material management, and aircraft disassembly.
These units collectively offer aircraft operators and owners worldwide a range of cost-effective solutions aimed at prolonging the lifespan of their assets or facilitating their disposal in an economically viable and environmentally sustainable manner. Notably, Vallair holds a prominent position in the cargo conversion market and is recognized for its expertise in trading and leasing narrowbody, widebody, and regional aircraft.
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