2025 Winner: Most Impactful Solution MRO
In 2025, Delta deployed foam engine core washing across seven stations in North and South America. The maintenance-based intervention reduced annual fuel burn by 1.4 million gallons while supporting reliability and maintenance performance.
Implementation Process: Deployment and Station-Level Activation
The engine foam wash program was implemented in collaboration with AeroCore, working with Delta’s Propulsion Engineering and Line Maintenance teams to develop fleet- and station-specific procedures. Following trials, tooling development, and certification for each engine fleet, deployment was prepared across selected stations.
AeroCore provided the required equipment on site, performing the wash at the gate or remote pad, with Delta technicians supporting engine access and idling. The process usednucleated foam technology that enables detergent to adhere to airfoil surfaces and penetrate deeper into the engine core. Fleet-specific tooling, developed by Delta Engineering, ensures the wash is conducted without introducing cabin odors.
Before activation at each station, Delta reviewed network deployment plans and maintenance presence, engaging local Delta and municipal leaders where required. A joint activation plan between Delta and AeroCore addressed regulatory requirements, weather conditions, and operational constraints prior to rollout.
Measurable Impact: Operational Integration and Network Expansion
Operational Impact
In 2025, 7 key stations conducted approximately 75% of all engine core washes, with over 3,300 washes completed. Three additional stations are in the process of activation, and one is under review for 2026. Once active, the foam wash process is expected to become the primary engine wash program for Delta TechOps.
Environmental Impact
Replacing the traditional water wash program results in fuel savings of up to 4 million gallons per year, directly reducing carbon emissions, operating costs, and demand on natural resources. Additionally, all wash effluent is captured and treated in compliance with local regulations to protect local water systems.
Additional Impact: Operational Integration and Cross-Functional Coordination
The program embedded fleet-specific procedures, tooling, and certification into routine maintenance operations through structured collaboration between AeroCore and Delta Engineering and Line Maintenance teams.
Industry Learnings: Scaling Engine Core Cleaning in MRO Operations
This case innovation demonstrates how engine core washing, implemented through routine maintenance, can meaningfully reduce fuel burn and associated emissions from flight operations. Expansion to additional stations and evaluation of further use cases reflect a deliberate, stepwise approach to embedding proven, high-impact MRO practices into standard operating procedures.
Delta’s case provides a practical example of how engine washing can be structured, certified, and scaled within regular maintenance operations, while leaving room for further expansion and potential environmental performance gains.