Passengers on Air India’s flagship Mumbai-to-Newark route found their travel plans upended in the early hours of October 22, 2025, after flight AI-191 was forced to make a precautionary return to Mumbai just three hours after takeoff. The incident, attributed to a suspected technical malfunction, has shone a spotlight on the operational challenges facing one of India’s most important international air corridors—and raised fresh questions about ongoing maintenance and passenger care in the country’s aviation sector.
According to reports from India.com and The Statesman, the Boeing 777 aircraft departed from Mumbai’s Chhatrapati Shivaji Maharaj International Airport at 1:15 am India Standard Time, bound for Newark Liberty International Airport in the United States. The journey, which typically takes over fifteen hours, was abruptly cut short when the flight crew, three hours into the trip, detected what they described as a “suspected technical issue.”
“The crew of Flight AI191 operating from Mumbai to Newark on Oct 22 made a precautionary air-return to Mumbai due to a suspected technical issue. The flight landed safely back in Mumbai and the aircraft is undergoing necessary inspections,” an Air India spokesperson said in a statement published by The Statesman. The exact nature of the malfunction remains unclear, with both the airline and regulatory authorities yet to release further details pending a thorough inspection of the aircraft.
After the safe landing, the aircraft was immediately taken out of service for a comprehensive inspection. The airline’s swift action, while disruptive, was in line with international safety protocols. “Safety of our passengers and crew is always our top priority,” the Air India spokesperson emphasized, echoing the industry’s standard refrain in such situations.
The ripple effects of the incident were felt on both sides of the globe. Not only was the outbound flight AI-191 cancelled, but its return leg—AI-144 from Newark to Mumbai—was also called off. Passengers who had already boarded or were waiting in Newark were notified of the cancellation and subsequent arrangements. In Mumbai, the airline scrambled to provide hotel accommodation and alternative flights for those stranded by the disruption. “Hotel accommodation and other flights have been arranged for passengers stranded in Mumbai, while passengers in Newark have also been informed. Necessary arrangements are being made for them,” Air India confirmed, as reported by India.com.
Despite the airline’s efforts to mitigate inconvenience, uncertainty lingered for many travelers. The total number of passengers affected was not immediately disclosed in the preliminary statements, leaving some to speculate about the full scale of the disruption. For those with connecting flights, business commitments, or family reunions ahead, the sudden change of plans was more than just a logistical headache—it was a source of considerable stress.
The timing of the incident is notable, coming just days after another high-profile technical snag grounded an Air India Boeing 787 Dreamliner in Milan. On October 17, 2025, a Delhi-bound Air India plane encountered a technical issue upon landing at Milan’s Malpensa Airport, stranding more than 250 passengers just ahead of the Diwali holiday. The airline responded by scheduling a special flight on October 19 to bring home the 256 affected travelers, while also providing hotel accommodation, meals, and the option of full refunds or complimentary rescheduling. “Air India had extended all immediate assistance to affected passengers, including hotel accommodation and meals. Full refunds or complimentary rescheduling were also offered as per passenger preference,” The Statesman reported.
These back-to-back incidents have prompted renewed scrutiny of Air India’s maintenance protocols, especially on its long-haul international routes. The Mumbai-Newark corridor, in particular, has seen its share of technical hiccups in recent months. On August 16, 2025, another Air India flight on the same route was cancelled before departure when a maintenance issue was detected during pushback. The resulting delay caused the operating crew to exceed mandatory flight duty time limitations, making it unsafe and impermissible for them to proceed with the journey. “A maintenance task was identified just as the aircraft was preparing for departure. The subsequent delay caused the operating crew to exceed mandatory flight duty time limitation norms, making it unsafe and impermissible for them to continue,” the airline explained, according to The Statesman.
Such disruptions, while relatively rare in the broader context of global aviation, can have outsized effects on passenger confidence, especially when they occur in quick succession. Industry analysts note that India’s aviation sector, which has grown exponentially over the past decade, now faces the dual challenge of maintaining rapid expansion while ensuring world-class safety and reliability standards. The Mumbai-Newark route, a vital link for business travelers, students, and families alike, is emblematic of these broader pressures.
For Air India, the immediate priority is clear: a thorough investigation into the technical cause of the October 22 incident, and swift corrective action to prevent future occurrences. The airline has pledged full cooperation with regulatory authorities and has assured passengers that their safety remains paramount. “The aircraft is undergoing necessary inspections,” the spokesperson reiterated, underscoring the company’s commitment to transparency and accountability.
Meanwhile, the Directorate General of Civil Aviation (DGCA), India’s chief aviation regulator, is expected to monitor the situation closely. In the wake of previous incidents, the DGCA has taken a “strict view” of crash investigations and maintenance lapses, sometimes seeking direct responses from both the airline and the Ministry of Civil Aviation. The regulatory environment, already stringent, may grow even more so if further issues come to light.
For passengers, the experience serves as a sobering reminder of the unpredictable nature of air travel—even in an era of advanced technology and rigorous safety checks. While the vast majority of flights operate without incident, the rare occasions when things go awry can disrupt lives and plans in an instant. The key, say experts, is not just how airlines respond in the moment, but how they learn from each episode to improve systems and restore trust.
As of now, the cause of the technical problem on AI-191 remains unknown. Passengers on both sides of the route are left to await further updates, hopeful that their next journey will be smoother—and grateful, at least, that safety was never compromised.