Preventing $10 million in aircraft downtime through engine delivery at ‘jet speeds’

In 2013, an Airbus A320 at Varna Airport in Bulgaria encountered heavy winds while landing on runway nine. The aircraft touched down significantly beyond the designated touchdown zone, veered off the runway, crossed a perimeter road, and collided with a fence. Fortunately, only two of the 172 passengers on board sustained minor injuries, and all were successfully evacuated. The incident resulted in irreparable damage to one of the aircraft's 5.5 metric ton engines, a critical component with a replacement cost of $10 million USD. The cause of the accident was determined to be beyond anyone's control, attributed to unforeseen weather conditions.

Once the airline ensured the safety of all passengers and crew, their focus shifted to getting the aircraft back into operation. This process involved complying with local regulations and standards for airplanes to guarantee total safety. The airline committed to a thorough assessment and repair process, highlighting their dedication to maintaining high safety standards in aviation.

A new engine was ordered immediately, with insurers covering the costs for both the engine and its transport from the U.S. to Bulgaria. The only constraint was time: the engine needed to be transported and installed within specific limits. World Courier’s reputation for reliable transport when time is critical meant we were often called upon to take swift action, which is exactly what our customer did.

World Courier had just 48 hours from the time of the call to arrange the export of the engine and meet the insurance company’s requirements. Our team collaborated closely between the U.S. and Bulgaria to ensure the engine met U.S. customs requirements with only hours to spare. Once the shipment was cleared, World Courier coordinated the pick-up, and the engine successfully departed from the U.S.

The initial plan involved sending the engine directly from Dallas to Frankfurt, transferring it to Bulgaria, and finalizing customs clearance at the border. However, Frankfurt customs initially requested a $2 million USD guarantee for the road customs transfer to Bulgaria, which proved unfeasible within the tight timeframe. Leveraging our extensive on-the-ground customs expertise, we assured EU customs agents that the engine complied with all necessary regulations, eliminating the need for the customs bond. This knowledge was instrumental in facilitating a smooth clearance process and ensuring the timely transport of the engine. Once it was cleared into the European Single Market, the free movement of goods between member states allowed for its transfer into Bulgaria. World Courier had prearranged a special truck to transport the engine from Frankfurt to Sofia.

The engine was delivered on time, and in perfect condition to Lufthansa Technik, who did all the necessary assembly of the engine and then mounted it to the aircraft.

Quick action and customs expertise successfully averted the loss of millions of dollars, returning a revenue-generating aircraft to normal operations. From start to finish, the project took less than a week.

For our customers, speed is critical to ensure their business continuity. Learn more about our industrial solutions, or get in contact with an expert.