Star Air Partners with HAL to Establish Dedicated MRO Facility for Embraer Aircraft in India

In a significant development for India's aviation sector, Bengaluru-based regional carrier Star Air has entered into a strategic partnership with Hindustan Aeronautics Limited (HAL) to set up a dedicated Maintenance, Repair, and Overhaul (MRO) unit for Embraer aircraft at HAL's Ozar facility near Nashik, Maharashtra. This collaboration marks a pivotal step in enhancing indigenous MRO capabilities for regional aircraft in India.

Strengthening Domestic MRO Capabilities

The new MRO unit aims to provide comprehensive support for Star Air's fleet of Embraer jets, including the ERJ 145 and E175 models. Previously, such aircraft required maintenance services from overseas hubs, incurring substantial costs. By establishing this facility, the partnership seeks to reduce dependency on foreign MRO centers and bring significant cost savings to Indian airlines.

HAL's Nashik facility, traditionally known for its defense aircraft production, has been undergoing upgrades to accommodate civil aviation requirements. The facility now boasts advanced tooling, skilled labor, and safety infrastructure to support heavy maintenance, structural repairs, and eventually engine and component services for Embraer aircraft.

Comprehensive Support and Training Initiatives

Under the Memorandum of Understanding (MoU), HAL will provide full MRO support for Star Air's Embraer fleet and other aircraft under its contracts. This includes complete aircraft painting services and the conduction of training programs for Star Air's workforce. HAL's expertise in aircraft maintenance, coupled with its state-of-the-art facilities, is expected to enhance the operational efficiency and safety standards of Star Air's fleet.

Expansion of HAL's Civilian MRO Services

This collaboration signifies HAL's expansion into the civilian MRO sector. In recent months, HAL's Nashik facility has successfully overhauled Embraer aircraft and an Airbus A320neo for IndiGo, marking its first ventures into civilian aircraft maintenance. The partnership with Star Air further solidifies HAL's commitment to diversifying its operations and contributing to the growth of India's civil aviation industry.

Economic Implications and Industry Impact

Experts estimate that Indian airlines spend approximately ₹15,000 crore annually on MRO services abroad. The establishment of this dedicated MRO unit is expected to retain a significant portion of this expenditure within the country, fostering economic growth and job creation in the aviation sector. Industry leaders have lauded the initiative for its potential to boost local employment and stimulate business opportunities in the Nashik region.

About Star Air

Star Air, the aviation arm of the Sanjay Ghodawat Group, is an Indian regional airline headquartered in Bengaluru. Operating since January 2019, the airline has expanded its network under the Government of India's UDAN (Ude Desh ka Aam Naagrik) scheme, connecting underserved regions across the country. As of 2025, Star Air operates an all-Embraer fleet, comprising ERJ 145 and E175 aircraft, and serves 29 domestic destinations.

About Hindustan Aeronautics Limited (HAL)

HAL is a state-owned aerospace and defense company headquartered in Bengaluru, Karnataka. Established in 1964, HAL has been a cornerstone of India's defense manufacturing sector. In recent years, the company has diversified its operations to include civilian aircraft maintenance, aiming to bolster India's self-reliance in aviation services.

This collaboration between Star Air and HAL represents a significant milestone in India's journey toward self-sufficiency in aircraft maintenance and underscores the growing synergy between the country's defense and civil aviation sectors.