Fuel is one of the highest operating costs for airlines. Yet many carriers may be missing significant savings hidden in how individual aircraft are flown, according to a
The company argues that the biggest opportunities for fuel savings are no longer found through new aircraft or engines alone, but by using data from each aircraft to optimise every stage of flight
Its AI-powered OptiFlight platform can reduce fuel consumption by up to 3% per flight, with savings adding up to around $50,000 per aircraft annually and lower carbon emissions.
Digital twins for every aircraft
Traditional flight planning tools rely on generic aircraft performance models for the type. SITA’s OptiFlight creates a digital twin of each aircraft. The system combines Quick Access Recorder (QAR) data, machine learning and high-resolution 4D weather forecasts to model how each airframe performs in real-world conditions
This allows the software to recommend the most fuel-efficient climb speeds, cruise profiles, descent paths and routing for each specific aircraft rather than relying on standard fleet-wide assumptions.
According to SITA, the technology has already been deployed on more than 2,500 aircraft worldwide
Small improvements add up
Fuel savings often come from incremental operational improvements rather than dramatic changes
SITA says its optimisation tools can deliver:
- Up to 5% reduction in climb fuel burn
- Around 3% cruise fuel savings
- Up to 3% average fuel savings across an entire flight
- Flight-by-flight verification of actual savings rather than theoretical estimates.
Because fuel is one of an airline’s largest operating expenses, even a one- or two per cent reduction can translate into millions of dollars across a fleet
Using SITA’s estimates, a 200-aircraft fleet could achieve around $9.8 million in annual net savings, equivalent to nearly $50,000 per aircraft.
No cockpit modifications required
Importantly, the platform does not require airlines to install new cockpit hardware
Recommendations are delivered directly to pilots through ACARS communications or the OptiFlight Electronic Flight Bag (EFB) interface. Post-flight analysis compares predicted and actual fuel consumption to refine the aircraft’s performance model continually.
The system analyzes 40 flight parameters to provide aircraft-specific recommendations while integrating with existing airline workflows.
Auditable results back sustainability claims
With regulations like the EU Green Claims Directive requiring verified data and penalising “greenwashing” claims, airlines need to prove that they are truly reducing their fuel burn and emissions
The OptiFlight digital tool can help airlines substantiate real-world fuel savings. It generates a fuel consumption prediction before the aircraft departs, operates the flight, and compares the fuel-savings data with auditable results.
Real-world airline adoption
Airlines have already adopted the technology as part of wider fuel-efficiency programmes
Earlier this year, ITA Airways announced it was rolling out SITA OptiFlight across its fleet to optimise climb performance using AI and aircraft-specific data. The airline expects to save more than 7,100 tonnes of fuel and reduce CO₂ emissions by over 22,100 tonnes across 2025 and 2026.
Airbus focuses on descent
SITA is not the only company seeking ways to optimise airline fuel consumption. Delta Air Lines selected Airbus’ Descent Profile Optimisation (DPO) tool to reduce fuel burn on descent and approach—one of the most fuel-intensive phases of flight.
Airbus installed DPO on 270 Delta aircraft, including narrowbody A319, A320, A321 and widebody A330s.
Why optimising flights matters
Airlines operate on narrow margins, with IATA predicting the industry will see a global profit of only 3.9% in 2026. Fuel accounts for up to 30% of airline operating costs. Airlines need to ensure fuel efficiency to stay in the black.
The airline industry has committed to NetZero 2050 targets, but lowering the environmental footprint requires higher supply levels of sustainable ahnologies that could take decades to deliver.
Operational improvements resulting from AI-powered technologies like SITA’s OptiFlight and Airbus’ DPO can help airlines reduce fuel costs and emissions immediately
News
Air TransportSustainabilityfuel burnOptiFlightSITASustainability
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