In an industry often criticized for its ecological footprint, a significant transformation is taking shape. Envision a jet engine initially designed for one aircraft, finding new purpose on another, rather than being discarded. This is not a futuristic concept; it is a reality as the aviation sector increasingly adopts principles of the circular economy.
The circular economy concept revolves around altering the traditional “take, make, dispose” approach to maintaining products and materials within the economy for as long as feasible. By maximizing the value extracted from resources in use and aiming to eliminate waste, these principles focus on reduction, reuse, and recycling whenever possible. Aviation is now embracing these concepts, reshaping its methods for constructing, maintaining, and decommissioning aircraft, while influencing strategic business practices throughout the sector.
The industry also faces the challenge of ensuring the safety of sustainable initiatives, confirming that recycled materials and eco-friendly aviation fuels adhere to strict regulatory requirements.
Transitioning from linear to circular: A new approach
The aviation industry’s journey toward incorporating circular economy practices is still in its nascent stages, yet progress is accelerating. In the past, retired planes would typically sit abandoned in deserts, with their components either inconsistently salvaged or left to decay.
Todays linear lifecycle is evolving into a more restorative model. With the introduction of advanced recycling and refurbishment methods, more than 90 percent of the weight of decommissioned aircraft can now be reused or recycled. Approximately 40-50 percent of an aircraft can be salvaged as operational parts, and most of the rest is converted back into raw materials.
Remarkably, nearly all components of contemporary jet engines are recyclable or reusable under optimal conditions, showcasing the advancements made in circular innovation. This shift is not solely about eco-friendliness; it’s also economically advantageous. Once an aircraft has reached the end of its operational life, it is now regarded as a valuable resource rather than mere waste. Key components are removed, assessed, and restored to “as-good-as-new” condition.
Engines, often the most significant asset on an aircraft, are central to this transformation. In many instances, a used engine in good condition holds a higher value than the aircraft from which it was taken. These power units can be repositioned in another plane or entered into a leasing pool, prolonging their operational lifespan for years. One airline’s decommissioned engine can become a cost-efficient upgrade for another.
Aeras Aviation has witnessed this change firsthand. Initially operating as a standard parts dealer, we have grown into a comprehensive lifecycle partner for some of the world’s leading aviation firms—such as Lufthansa, DHL, Air France, and Delta Airlines. While embracing circularity offers both economic and environmental returns, safety continues to be a non-negotiable priority within the sector.
Giving engines a second chance
Jet engines are prime examples of circular economy in action. These complex systems are designed for multiple overhauls. Each refurbishment process—entailing rigorous inspections, repairs, and part replacements—adds several years of usable life. Components previously deemed obsolete are transformed into revenue-generating, service-ready assets.
Parts that cannot be reused are often recycled. High-value metals such as titanium, nickel, and cobalt are melted down and reintegrated into the aerospace supply chain. An engine that has served its time today can become part of a new turbine blade tomorrow—or even find utility in an entirely different industry.
Full lifecycle programs are enhancing capabilities for airlines and maintenance providers to prolong the useful life of engines across the industry.
Rather than acquiring new engines, many organizations choose to source, refurbish, and redeploy existing engines—extending not only the lifespan of the hardware but also significantly cutting costs and carbon footprints. This is sustainability at scale.
The economic rationale behind circularity
This approach is no longer confined to niche markets. Airlines navigating a cost-sensitive, post-pandemic landscape are now “maximizing their assets” longer than ever—and they require reliable, certified partners to assist them in this process. The price of new aircraft continues to climb—planes like the Boeing 737 or Airbus A320 exceeding $100 million—while global supply chain issues have made new deliveries less reliable.
As a result, the market for used serviceable materials (USM) is thriving. Repurposing or refurbishing engine components according to OEM standards can save airlines 20-40 percent compared to purchasing new ones. This reality is becoming increasingly evident to airlines and maintenance, repair, and operations (MRO) providers, as well as to investors.
Simultaneously, regulators and environmentally conscious investors are applying pressure on the aviation sector to broaden its responsibilities beyond flight emissions. The industry’s commitment to achieving net-zero emissions by 2050 necessitates a comprehensive re-evaluation—circularity plays a pivotal role in that vision. The European Union’s advocacy for a circular economy, including more stringent regulations on aircraft dismantling and waste management, underscores that this is not merely a trend, but a legislated shift. Organizations that proactively adapt to these changes will not only ensure compliance but also position themselves as leaders.
A shift in mindset for the industry
Embracing circularity also paves the way for innovative business models such as engine leasing, power-by-the-hour agreements, and predictive maintenance strategies. These models enhance the longevity of engines while generating ongoing revenue and fostering stronger customer relationships.
Ultimately, aviation is demonstrating that sustainability and profitability can coexist and even mutually enhance each other. If a highly regulated and safety-critical industry like aviation can successfully implement circular practices, then it sets a precedent that other sectors can follow. This presents an enormous opportunity for business leaders across various fields.
Responsible growth
The circular economy in aviation is no longer just a theoretical concept—it is a viable, scalable approach that is already redefining the creation of value. It emphasizes viewing every decommissioned component not as waste, but as an opportunity. It encourages extending the life of existing resources instead of defaulting to new acquisitions.
By rethinking what can be achieved at the end of an engine’s lifecycle, we not only preserve resources but also contribute to a more intelligent and responsible future for air travel.
Demetrios Bradshaw is the CEO of Aeras Aviation.