CABIN. Exclusive: Pitch PF2000 economy seat AIRCRAFT MANAGEMENT. Musical chairs British Airways fleet refits. Mood control Cabin management systems

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1 AIRCRAFT CABIN Volume 1 Issue 1 April 2012 MANAGEMENT Musical chairs British Airways fleet refits Mood control Cabin management systems Exclusive: Pitch PF2000 economy seat

The meal an airline serves can influence customer satisfaction, but it also has implications on the weight of the aircraft (photo: Cathay Pacific) Are you being served?

2 The meal an airline serves can influence customer satisfaction, but it also has implications on the weight of the aircraft (photo: Cathay Pacific) Are you being served? AIRLINES ARE LOOKING FOR GALLEYS THAT DELIVER COST-EFFECTIVE, PRACTICAL DESIGNS THROUGH INNOVATION, WHILE ALSO INTRODUCING TECHNOLOGIES THAT CATER FOR CUSTOMERS EVER-EVOLVING EXPECTATIONS. KEITH MWANALUSHI INVESTIGATES HOW GALLEY AND INSERT MANUFACTURERS ARE REACTING TO THESE CHALLENGES The catering paradigm for the industry was established over 40 years ago, at the dawn of the jet age. Today, economic pressures give the industry an opportunity to rethink how to store and prepare food onboard, using new and more efficient galley solutions that take installation, weight, reliability and operational factors into account. There are several ways in which concerns have been taken into consideration, says Jeff Luedeke, Vice President, Sales and Marketing for TIMCO Aerosystems, describing the factors that influenced the design of the FeatherWeight galley solution. We have, for example, increased our use of innovative, lightweight materials, like advanced composites. In addition, our engineers use finite element modelling (FEM) to identify where structures need strength for safety, stability and support, while at the same time revealing areas in our products that can be constructed of far lighter materials in the absence of a need for load-bearing strength. The FeatherWeight galley went onto the production line in 2011, and the first installation was on a Japan Airlines Boeing 767. Luedeke adds that the affiliation with TIMCO s airframe MRO division helps Aerosystems respond to airlines concerns and desires related to product longevity and support. We understand where parts failures have added cost and frustration, and we recognise how part count reduction or design improvements can improve the product life 28 AIRCRAFT CABIN MANAGEMENT April 2012

Ó Jeff Luedeke (photo: TIMCO Aerosystems) experience for airlines. That experience feeds into our design process as we consider maintainability and product integrity.

A frequent request is the ability to modify interior products without having to replace all interiors elements.

a coffee maker for an espresso machine. Airlines face three large cost drivers that have continued to grow over the years: employees, maintenance and fuel.

3 Ó Jeff Luedeke (photo: TIMCO Aerosystems) experience for airlines. That experience feeds into our design process as we consider maintainability and product integrity. Luedeke emphasises the importance of listening to airlines when it comes to adapting products to changing market needs. A frequent request is the ability to modify interior products without having to replace all interiors elements. Our work on our FeatherWeight galleys is a good example of how we respond by making it possible for airlines to swap out galley inserts without significant modification changes, for example changing a coffee maker for an espresso machine. Airlines face three large cost drivers that have continued to grow over the years: employees, maintenance and fuel. Luedeke states that the FeatherWeight galley solution addresses the latter two elements, and by doing so, operators are drawn to the benefits. Galley manufacturer Driessen-Zodiac Aerospace has developed the Max Flex2 (MF2), which is now an integral part of the Boeing 737 Sky Interior cabin. Abraham Sarraf, Director, Sales and Marketing says the market response for the MF2 concept has been successful with over 1,200, 737 ship sets sold. Besides overall aesthetic improvements to the galley, Driessen designed MF2 galleys with four areas in mind: weight reduction, modularity, reliability, and cost and installation time. Weight reduction was achieved by reducing the number of parts by over 300 screws and inserts, with an overall reduction of 10% from our previous Maxflex galleys, which were already the lightest in the market, Sarraf says. In terms of modularity, the configuration is designed to allow for more than four options per cavity, according to Sarraf. All the available options are pre-certified to minimise cost, and to enable airlines to change the galley at any time during the lifetime of the aircraft to meet airline requirements for different routes or marketing changes. The galley is equipped with LED lighting, fewer parts, milled trim doors and new placards made of more durable materials. The galley is large enough to accommodate full-size trolleys, but small enough to fit through the aircraft door, helping to reduce the installation time. Sarraf adds that by using quick release fittings, the hardware is reduced from 150 to less than 10 parts. This saves six hours in installation time. FLEXIBLE THINKING In the past, some airlines have reported installing galleys that had serious repercussions on their operations, including a high risk of damage during galley-cart loading at turnaround, and a cramped working environment for cabin crew during meal service. Sarraf says Driessen found its way around such concerns by working closely with Boeing. MF2 galleys were designed jointly with Boeing engineering to maximise working areas, and to include ergonomic analysis to prevent injuries and allow flight attendants to access all compartments and equipment without over-stretching or bending too low. TIMCO Aerosystems is tackling such challenges with the idea that standardisation is key to minimising disruption and damage during galley servicing, as Luedeke explains: This standardisation applies to the galley design itself, the galley carts and perhaps most importantly the location of the galleys in the cabin. Airlines and original equipment manufacturers (OEMs) have been moving in this direction, and we are starting to see this become a focus on new aircraft with the implementation of so-called flex zones areas in the cabins that OEMs designate as structurally sound for galley and lavatory locations. While structural and weight requirements are critical elements Advanced composite materials make up TIMCO s FeatherWeight galley solution (photo: TIMCO Aerosystems) Ô An ergonomic analysis can prevent flight attendents from over stretching or bending too low in the galley (photo: British Airways) 30 AIRCRAFT CABIN MANAGEMENT April 2012

that are considered in designating flex zones, traffic flow and optimal workspace access are also taken into consideration.

On older fleets like the DC-9, the galley was frequently located aft of the door, which required multiple turns of cabin service carts raising the risk of cabin damage and disruption of passenger

Similar changes have been implemented on narrowbody aft galleys, which are now behind the rear lavatory positions and adjacent to doors, and on galley positions in new widebody cabins, he adds.

Driessen is tackling the issue with its modular galley solution for current production Airbus A320s.

4 that are considered in designating flex zones, traffic flow and optimal workspace access are also taken into consideration. An example of how this has created a positive impact, according to Luedeke, is the location of the forward galley on most narrowbodies in relation to the R1 door on the right side of the cabin. On older fleets like the DC-9, the galley was frequently located aft of the door, which required multiple turns of cabin service carts raising the risk of cabin damage and disruption of passenger loading flow. Today, the position is almost universally located forward of the R1 door, making access for servicing direct and eliminating through-cabin transit. Similar changes have been implemented on narrowbody aft galleys, which are now behind the rear lavatory positions and adjacent to doors, and on galley positions in new widebody cabins, he adds. An issue that comes up when talking to airlines is the ability to reconfigure the galley after delivery in order to cater for seasonal catering demands or route-specific requirements. Driessen is tackling the issue with its modular galley solution for current production Airbus A320s. The modification Standardisation applies to the galley design itself, the galley carts and perhaps most importantly the location of the galleys in the cabin Jeff Luedeke, TIMCO Aerosystems kits are pre-certified, which avoids the need to re-certify. Driessen claims that the new A320 galleys have achieved a reduction in weight of 15%, with relative savings in maintenance and installation time. WASTE MANAGEMENT In the 1970s, when today s galleys were conceived, there was less focus on how to manage waste handling onboard the aircraft, which is a key step to performing recycling when on the ground. There is now greater demand for airlines to implement waste segregation initiatives in the galley during flight. Luedeke says TIMCO has adapted galley inserts to accommodate a variety of airlinespecific waste recovery systems and holding receptacles. He adds that beyond the design of collection and sorting containers for recyclable waste and onboard systems that have been accommodated through adaptation of new inserts in the galley, TIMCO engineers have also worked on designs that allow airlines to recycle potable water efficiently. This was achieved without adding significant weight or complexity that would add to ongoing maintenance costs, he says. Studies have identified that over half of all aircraft cabin waste can be recycled, with newspapers, magazines and cans making up by far the majority of waste by weight. There has been a number of individual recycling The difference is in the air. People used to travel far to get a change of air. Not any more! With CTT s humidification system Cair now available on all three modern aircraft models from Boeing and Airbus crew and passengers can enjoy a healthy climate from the moment they step on board. CTT Systems AB is a Swedish technology group active in the aviation industry, specialising in humidity control systems for commercial aircraft. Customers include both aircraft manufacturers and airlines. See Welcome to visit us at Aircraft Interiors, Hamburg March 27-29, in hall B5, stand 5A45 and feel the difference!

initiatives in recent years, including collections of cans by Thomas Cook and First Choice. However, there were many barriers to the implementation of larger scale recycling of onboard waste.

limit current galley designs. As part of the SPICE architecture, Airbus has designed a customisable range of equipment with which airlines can implement waste segregation initiatives.

5 initiatives in recent years, including collections of cans by Thomas Cook and First Choice. However, there were many barriers to the implementation of larger scale recycling of onboard waste. ADDING SPICE Airbus claims that its future galley concept, Space Innovative Catering Equipment (SPICE), will solve problems associated with recycling waste and tackle several other key issues that limit current galley designs. As part of the SPICE architecture, Airbus has designed a customisable range of equipment with which airlines can implement waste segregation initiatives. The key enabler is the open top of the folding service cart, which allows the different materials to be collected and segregated easily. To save weight, the SPICE concept will put today s standard meal trays into lightweight boxes, instead of trolleys. The foldable service carts are then used to transport the boxes during passenger service. With these changes, Airbus said SPICE can save 400 to 600kg of weight, and enough space to gain two to three economy seats on a typical widebody aircraft seating 250 to 300 passengers. Airbus is convinced that these benefits will be available with minimal change to today s ways of serving passengers, and preparing food for loading onto aircraft. ADAPTABLE TECHNOLOGIES Galley insert design is also taking on new innovation. In 2011, Iacobucci HF introduced a new lightweight microwave oven developed by its German subsidiary, Modular Galley Systems (MGS). Lucio Iacobucci, group President, says that the product has been received well since it was unveiled at Aircraft Interiors Expo Americas in Seattle last year. It is extremely light, and our research and development department has optimised the microwave internal volume, therefore maximising its usability, says Iacobucci. The MGS microwave weighs in at only 14kg, with an internal volume of just over 12 litres. It also features a programmable digit pad with software that enables the operator to customise heating programmes according to requirements. The power level can be manually adjusted for various heating purposes such popcorn heating, defrosting or baby bottle heating. Iacobucci says that innovative technologies are key to responding to demanding customers, and the microwave is specifically designed to aid the duties of the growing number of onboard chefs. An optimum quality of cuisine on the aircraft is a decisive factor in meeting the needs of first and business class passengers. All MGS products are designed with minimum maintenance, which helps to keep airlines budgets on target. Inserts such as ovens, beverage makers and other equipment that are installed in today s galleys come in a variety of different sizes and lack standardisation. They are designed to be permanently installed in the galley, only to be removed for repair or servicing. Could standardising galley inserts be the way forward in terms of design? Iacobucci believes so: Yes, I do believe that standardising galley inserts could be generally possible. I still think that there are always customers who need products that are conceived to make a difference on board. Today s business environment is a continuous challenge, and to win this challenge, a company has to fear obsolescence through continuous innovation and development. Summarising, TIMCO Aerosystems Luedeke stresses the importance of customer interaction in developing efficient galley design. As we engage with our customers, we continue to listen to their concerns and past experiences with galleys, lavatories, seats and other interior products. We take their feedback into account as our designers continuously work to develop new interiors solutions with fewer parts, lower weight and less complexity. Galleys are being modified to cater for onboard chefs (photo: Etihad) PRIME CUTS Onboard chefs are being introduced increasingly to cater to the culinary taste of premium passengers, which means that modifications to the galley are necessary in order to accommodate onboard food preparation. Etihad Airways is progressively introducing qualified chefs across all its First Class destinations. The chefs are provided with a pantry stocked with cuts of meat, sauces, par-cooked items, spices and freshly chopped vegetables. The pantry allows them to prepare for service and personalise dishes in the same way as chefs in a restaurant kitchen. Tools not typically seen on an aircraft, such as a whisk and other utensils, are also at their disposal. The airline has hired nearly 110 chefs, who will also contribute to menu development for both lounges and flights. Ó This lightweight microwave developed by MGS is proving to be a popular solution (photo: MGS) 32 AIRCRAFT CABIN MANAGEMENT April 2012

OVERVIEW: GALLEYS Today s business environment is a continuous challenge, and to win this challenge, a

HF Õ The storage efficiency of the Airbus SPICE concept could enable an airline to add 11 seats to a

WE VE ARRIVED...VISIT US AT STAND 5G22! DESIGN SEATING * OPERATIONS SYSTEMS OVERVIEW AIRLINES UPGRADES www.

com +44 (0)1737 788888 MATERIALS BUSINESS Design, refurbishment, manufacture and installation of interiors

Specialising in lavatories, galleys, seats, stowage s, baby cradles and VIP interiors.

6 OVERVIEW: GALLEYS Today s business environment is a continuous challenge, and to win this challenge, a company has to fear obsolescence through continuous innovation and development Lucio Iacobucci, Iacobucci HF Õ The storage efficiency of the Airbus SPICE concept could enable an airline to add 11 seats to a typical widebody aircraft cabin, while reducing overall weight (photo: Airbus) AIRCRAFT CABIN MANAGEMENT WE VE ARRIVED...VISIT US AT STAND 5G22! DESIGN SEATING * OPERATIONS SYSTEMS OVERVIEW AIRLINES UPGRADES (0) MATERIALS BUSINESS Design, refurbishment, manufacture and installation of interiors for all aircraft types. Specialising in lavatories, galleys, seats, stowage s, baby cradles and VIP interiors. MANUFACTURERS To subscribe, circulation@airtransportpubs.com To advertise, contact Kate Sloan: kate@airtransportpubs.com t: ACM_QP.indd 1 April 2012 EASA Part 21 G & J, EASA 145 certiﬁed 09/03/ :39 AIRCRAFT CABIN MANAGEMENT 33

1.6 M Manhours per year. 9 Heavy wide-body bays incl 3 A380 bays with paint facilities. More than 200,000 m 2 of apron & hangars

1.6 M Manhours per year. 9 Heavy wide-body bays incl 3 A380 bays with paint facilities. More than 200,000 m 2 of apron & hangars The Design, Engineering and Innovation team at Etihad Airways Engineering provides finest Innovations, Engineering and Production solutions to Etihad and customers from all over the world. Etihad Airways