New Unilode MRO boosts UK capacity

Rapidly increasing volumes and sustained expansion of e-commerce are reshaping ULD maintenance requirements at the UK’s busiest cargo hubs, driving a shift towards near-airport repair capacity. Unilode Aviation Solutions has opened a 27,000 sq ft maintenance, repair and overhaul site at Stud Brook Business Park in Castle Donnington to meet accelerating customer demand. Ross Marino, the company’s CEO, said the investment is in line with long-term growth patterns across European and global air cargo networks.

Proximity to East Midlands Airport has become crucial for integrators and airlines operating in fast cycle environments. The new facility provides higher throughput, shorter transmission distances, and greater network flexibility during peak periods.

Regional demand drives expanded capacity

East Midlands Airport’s role as the UK’s largest pure freight gateway has created ongoing pressure for faster ULD repair cycles. Operators need a near-instantaneous response, especially during late night and early morning rush hour periods. Unilode chose Castle Donnington for its connectivity to the airport and major road links, allowing faster transfers and reduced handling time.

Infrastructure capacity is fundamental to the operational purpose of the site. Additional repair lines, storage areas and separate work areas are designed to eliminate bottlenecks and stabilize service levels during increases in freight movement. The model moves more work to the Midlands region to support carriers and integrators seeking predictable availability and lower relocation requirements.

“Our new state-of-the-art East Midlands MRO services significantly increase our repair capacity, enhance our ability to handle larger volumes, and improve speed of service,” Marino said. “This allows us to better support both UK-based customers and international carriers with operations across Europe and the world. Our enhanced site workflow, modern infrastructure and specialist workforce elevate our ability to deliver consistent, high-quality ULD maintenance at scale.”

“Growth in e-commerce, express freight and integrated logistics operations at East Midlands Airport has led to a sharp increase in demand for ULD,” Marino said. “Customers increasingly require faster turnaround, higher reliability and greater flexibility in repair services. Expanding fleets and duplicating operations between integrators and carriers operating from EMA have also contributed to the need for additional, modernized ULD maintenance capacity.

“Castle Donnington offers exceptional connectivity – it is minutes from East Midlands Airport and close to major transport links including the M1, A50 and A453,” Marino said. “This allows for faster logistics movements, reduced transportation times for ULDs, and improved responsiveness to customers operating at or through the airport. The location supports the fast and reliable service levels required in high-volume cargo and passenger operations.”

Network integration and customer performance

The East Midlands opening strengthens Unilode’s European network and provides a buffer against congestion at other locations. The facility is integrated with global digital systems and standardized repair processes, ensuring continuity of service even during peak periods. Customers such as DHL, West Atlantic, Singapore Airlines, Aer Lingus, Finnair and TUI receive shorter processing times and improved ULD availability.

This investment reduces the need for long-distance transportation to repair centers, supporting aircraft utilization and on-time performance. The dedicated team of 30 is key to productivity, providing expertise in complex repairs and high-volume operational environments. The facility is designed to further scale activity as network cycles increase.

“The East Midlands facility is part of a broader investment program that includes new sites in Hong Kong and Singapore and refurbishments in Newark and Heathrow,” Marino said. “It enhances our European MRO coverage and enhances network resilience. The facility operates using global Unilode standards and digital processes and systems, ensuring consistent service levels, repair quality and data visibility across all sites.”

“Customers will benefit from faster repair lead times, improved ULD availability and reliability, reduced transport and handling times, increased operational support in EMA and across the UK, enhanced service continuity due to increased regional capacity, and enhanced sustainable supply chain,” Marino said. “These improvements support on-time performance, operational efficiency and cost effectiveness.

“The team has deep experience in ULD repair, handling and operational support,” Marino said. “Their expertise ensures high-quality, efficient maintenance is delivered even as demand increases. The size and skills of the workforce allow the facility to scale operations, maintain high productivity, and continue to meet the needs of major integrators and airline customers 24/7.”

Sustainability and long-term strategy

Environmental performance is an integral part of the new site. The facility runs on renewable energy, includes advanced waste management systems, and complies with BREEAM certification standards. Repair-based life cycle extension reduces the environmental impact associated with manufacturing new modules and reduces resource intensity across the network.

The sustainability profile is consistent with Unilode’s long-term strategy. Investments across global hubs are designed to reduce waste, enhance operational robustness, and support carrier demand for low-impact aviation services. The East Midlands is positioned as a scalable platform for further development as client activity increases.

“The grand opening represents an exciting step forward for our team in the East Midlands and our customers,” Balkins said. “Our new East Midlands MRO is designed to enhance our service capabilities, support growing customer demand and create a workplace that reflects our values ​​and ambitions.

“This facility reinforces our commitment to sustainable growth,” Balkins said. “By investing in a modern, efficient process powered by 100 percent renewable energy and compliant with BREEAM certification standards, we are ensuring that our work not only benefits our customers, but also our people and our planet.

“Our team in the East Midlands have already achieved great results, and this new facility enables us to grow our capabilities further,” Balkins said. “It supports our global growth and helps customers achieve maximum performance across their operations.”