Introduction
As MRO providers expand capacity to meet growing demand for aircraft maintenance, the focus is increasingly shifting beyond hangar space and turnaround times to the environmental footprint of the facilities themselves. For AAR, that shift is taking shape at its Greensboro Airframe MRO facility, where 7,770 solar panels installed across six buildings are expected to offset approximately 50% of the facility’s energy usage and reduce carbon emissions by around 2,000 metric tons annually.
The project is part of AAR’s broader approach to sustainability, which combines renewable energy with practical measures such as LED lighting, more efficient compressed-air systems, building automation, paperless maintenance and digital recordkeeping. At Greensboro, these initiatives are being integrated into the day-to-day realities of a large operational MRO facility, where safety, quality, productivity and aircraft turnaround remain paramount.
In this exclusive conversation with MRO Business Today, Jessica Garascia, Senior Vice President, General Counsel, Chief Administrative Officer and Secretary, AAR, discusses what drove the Greensboro solar project, the operational impact of reducing energy consumption, the challenges of introducing renewable infrastructure within an airport environment, and how sustainability can become part of future MRO facility development without compromising the fundamentals of maintenance operations.
Q – AAR has installed 7,770 solar panels across six buildings at its Greensboro Airframe MRO facility. What prompted AAR to undertake a project of this scale, and how does it fit into the company’s broader sustainability strategy?
Ans – AAR’s approach to sustainability focuses on practical initiatives that support our operations, team members, and communities. Across the Company, that includes workplace safety programs, environmental compliance and risk management, recycling and waste-reduction initiatives, energy-efficiency projects, and expanded use of digital maintenance processes. Many of these efforts are driven by opportunities identified at the local facility level, while others are implemented more broadly across the organization.
Solar panels have been part of our Component MRO facility in Amsterdam. We were pleased this project enabled us to expand this environmental benefit to our Airframe MRO network.
We are committed to understanding and managing our environmental impacts and look for initiatives that can reduce resource consumption, improve efficiency, and support long-term sustainability goals. The Greensboro solar panel installation is an example of an initiative that aligns with those broader efforts.
Q – The solar installation is expected to offset approximately 50% of the facility’s energy usage and reduce around 2,000 metric tons of carbon emissions annually. What does this mean from an operational perspective, and how do you see the project influencing the facility’s long-term energy strategy?
Ans – Beyond the cost savings and the emissions reduction, our solar array is a source of pride and a statement or permanence for our team members. The solar array is an investment in the future of the site and our team members. We are in the early stages of a new paint hangar project, and sustainable development is included in the design and equipment selection.
Q – MRO facilities are energy-intensive operations, particularly when it comes to hangars, lighting, climate control and aircraft maintenance equipment. Beyond solar power, what other areas of the MRO operation offer the greatest opportunities for reducing energy consumption and emissions?
Ans – Opportunities vary by facility, but areas we commonly evaluate include LED lighting upgrades, HVAC optimization, paperless maintenance processes, tablet-based inspections, and recycling and waste-reduction initiatives. We have also expanded digitization efforts, including electronic recordkeeping and document management, across our MRO network. These initiatives can help reduce resource consumption while improving operational efficiency. As an example, at our Greensboro facility, we estimate that LED lighting upgrades, investments in more efficient compressed air supplies, and building automation systems have helped reduce the site’s energy demand by approximately 30% since 2018.
Q – The Greensboro project required a solar feasibility study and glare hazard analysis in collaboration with the FAA and Piedmont Triad International Airport. What were some of the specific challenges of implementing renewable energy infrastructure within an airport environment, and what lessons has AAR learned from the project?
Ans – Piedmont Triad International Airport (PTIA) was very supportive of our project. They reviewed the initial plans and offered suggestions and guidance during the construction phase. Obtaining a crane permit near a runway was one of the biggest challenges we faced. Fortunately, between the FAA, PTIA, and our contractors, we were able to remain on schedule and on budget. Project logistics required close coordination, including to replace hangar roofing, install the solar array infrastructure, and finally install the solar panels, all while operating a large MRO.
Q – How is AAR balancing sustainability objectives with the core requirements of an MRO operation including aircraft turnaround times, productivity, safety, quality and cost efficiency?
Ans – At AAR, safety and quality are the foundation for how we evaluate all initiatives. Consistent with our core value, “Quality first. Safety always.” we seek opportunities that support sustainability objectives while also meeting the operational and customer requirements of the business. For example, paperless maintenance processes and electronic recordkeeping can help put information in the hands of technicians more efficiently, support accurate documentation and recordkeeping, and reduce paper consumption.
Q – As AAR continues to expand its MRO footprint, how important will sustainability considerations be when developing or upgrading future facilities? Could the Greensboro model potentially be replicated across other AAR locations?
Ans – Every facility is different, so we consider factors such as the nature of the operation, the physical characteristics of the site, and the potential impact of a project. While lessons learned from Greensboro may help inform future decisions, sustainability initiatives are evaluated based on the circumstances of each location.
Q – Looking at the wider MRO industry, where do you believe the biggest opportunities lie for aviation maintenance providers to reduce their environmental footprint while continuing to meet the growing demand for maintenance capacity?
Ans – While approaches will vary across the industry, we have found that practical operational improvements can make a meaningful difference. Examples include paperless maintenance processes, energy-efficiency investments, and waste-reduction initiatives. These types of efforts can help reduce resource consumption while supporting efficiency and day-to-day operations.
