Flight AI185 took off from Delhi at 11:34 am on Thursday and initially proceeded along its planned eastward route.

However, nearly four hours into the journey—while flying over Chinese airspace near Kunming—the airline discovered that the aircraft deployed for the route was not authorised to operate in Canada.

The aircraft, a Boeing 777-200LR, reportedly lacked the necessary regulatory clearance for Canadian operations.

Currently, Air India is permitted to use only its Boeing 777-300ER fleet on flights to Canada, highlighting how aviation approvals can be tied not just to airlines but to specific aircraft types or even individual planes.

Following the realisation, the aircraft was recalled mid-flight and ultimately landed back in Delhi after a total airborne time of 7 hours and 54 minutes. All passengers and crew disembarked safely, with no reported injuries.

In a statement, the airline cited an “operational issue” and said the decision to turn back was made in accordance with standard operating procedures.

It also apologised for the inconvenience caused and said arrangements—including hotel accommodation—were made for affected passengers, who were later rebooked on another flight.

The incident is expected to have significant financial implications. A long-haul aircraft like the Boeing 777 typically consumes 8–9 tonnes of fuel per hour, meaning the nearly eight-hour journey would have resulted in substantial operational costs for the airline.