Rising express volumes and sustained e-commerce expansion are reshaping ULD maintenance requirements at the UK’s busiest pure cargo hub, prompting a shift toward 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 chief executive, said the investment aligns with long-term growth patterns across European and global airfreight networks.
Proximity to East Midlands Airport has become critical for integrators and airlines operating in rapid-cycle environments. The new facility provides higher throughput, shorter transport distances, and greater network flexibility during peak periods.
Regional demand drives expanded capability
East Midlands Airport’s role as the UK’s largest pure cargo gateway has created sustained pressure for faster ULD repair cycles. Operators require near-instant responsiveness, particularly during late-night and early-morning express peaks. Unilode selected Castle Donnington for its connectivity to the airport and major road links, enabling faster transfers and reduced handling time.
Infrastructure capacity is central to the site’s operational purpose. The additional repair lines, storage areas, and segregated work zones are structured to remove bottlenecks and stabilise service levels during surges in cargo traffic. The model shifts more work into the Midlands to support airlines and integrators seeking predictable availability and lower repositioning requirements.
“Our new state-of-the-art East Midlands MRO significantly increases our repair capacity, strengthens our ability to handle higher volumes, and improves service speed,” Marino said. “This allows us to better support both UK-based customers and international carriers with operations across Europe and the world. The site’s enhanced workflow, modern infrastructure, and specialist workforce elevate our ability to deliver consistent, high-quality ULD maintenance at scale.
“Growth in e-commerce, express cargo, and integrated logistics operations at East Midlands Airport has driven a sharp rise in ULD demand,” Marino said. “Customers increasingly require faster turnaround, higher reliability, and greater flexibility in repair services. The expansion of fleets and frequency of operations among integrators and carriers operating from EMA also contributed to the need for additional, modernised ULD maintenance capability.
“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 enables faster logistics movements, reduced transport times for ULDs, and improved responsiveness for customers operating at or through the airport. The site supports the rapid, reliable service levels required in high-volume cargo and passenger operations.”
Network integration and customer performanceThe East Midlands opening strengthens Unilode’s European network and provides a buffer against congestion at other locations. The facility integrates with global digital systems and standardised repair processes, ensuring service continuity even during peak periods. Customers such as DHL, West Atlantic, Singapore Airlines, Aer Lingus, Finnair, and TUI gain shorter handling times and improved ULD availability.
The investment reduces the need for long-distance transfers to repair hubs, supporting aircraft utilisation and on-time performance. The 30-strong specialist team is central to throughput, bringing expertise in complex repairs and high-volume operational environments. The facility is structured to scale activity further as network cycles increase.
“The East Midlands facility is part of a wider investment programme that includes new sites in Hong Kong, Singapore, and refurbishments in Newark and Heathrow,” Marino said. “It strengthens our European MRO coverage and enhances network resilience. The facility operates using Unilode’s global standards, processes, and digital systems, ensuring consistent service levels, repair quality, and data visibility across all locations.
“Customers will benefit from faster repair turnaround times, improved ULD availability and reliability, reduced transport and handling times, greater operational support at EMA and across the UK, enhanced service continuity due to increased regional capacity, and a strengthened sustainable supply chain,” Marino said. “These improvements support on-time performance, operational efficiency, and cost-effectiveness.
“The team brings deep expertise in ULD repair, handling, and operational support,” Marino said. “Their experience ensures high-quality, efficient maintenance delivery even as demand increases. The size and skillset of the workforce allow the facility to scale operations, maintain high throughput, and continue meeting the needs of major integrator and airline customers 24/7.”
Sustainability and long-term strategyEnvironmental performance is an embedded component of the new site. The facility operates on renewable energy, incorporates advanced waste management systems, and is aligned with BREEAM certification criteria. Repair-based lifecycle extension reduces the environmental impact associated with manufacturing new units and lowers resource intensity across the network.
The sustainability profile is consistent with Unilode’s long-term strategy. Investments across global hubs are structured to reduce waste, strengthen operational durability, and support carrier demand for lower-impact aviation services. East Midlands is positioned as a scalable platform for further development as customer activity increases.
“The Grand Opening represents an exciting step forward for our East Midlands team and our customers,” Balkens said. “Our new East Midlands MRO has been designed to enhance our service capabilities, support increased customer demand, and create a workplace that reflects our values and ambitions.
“This facility reinforces our commitment to sustainable growth,” Balkens said. “By investing in a modern, efficient operation powered by 100 percent renewable energy and aligned with BREEAM certification standards, we are ensuring our work benefits not just our customers but our people and the planet.
“Our East Midlands team has already delivered outstanding results, and this new facility enables us to grow our capabilities further,” Balkens said. “It supports our global growth and helps customers maximise performance throughout their operations.”
