Aviation technology provider SITA says 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. The system creates a digital twin of each aircraft by combining Quick Access Recorder (QAR) data, machine learning and high-resolution 4D weather forecasts to model real-world performance, recommending 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. The optimisation tools can deliver up to 5% reduction in climb fuel burn, around 3% cruise fuel savings, and up to 3% average fuel savings across an entire flight. 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. The platform does not require new cockpit hardware; recommendations are delivered via ACARS communications or the OptiFlight Electronic Flight Bag interface. The system analyzes 40 flight parameters and generates auditable fuel consumption predictions to help airlines substantiate real-world fuel savings under regulations like the EU Green Claims Directive.