Nov 17th 2022 : An Air Malta Airbus A320-200 operating flight KM514 from Malta to Vienna was forced to return to its departure airport shortly after takeoff after smoke was reported in the flight deck.
The aircraft, registered 9H-AHS and carrying 170 passengers and seven crew members, departed Malta International Airport from runway 23. During the initial climb, the flight crew donned their oxygen masks, declared a PAN PAN PAN emergency, and reported smoke in the cockpit. The climb was stopped at approximately 2,000 feet, and the crew elected to return to Malta as a precaution.
The aircraft landed safely on runway 31 about 13 minutes after departure and came to a stop on the runway, where emergency services carried out an inspection. After no immediate hazards were identified, the aircraft taxied to the apron around eight minutes later. No injuries were reported.
Air Malta stated that passengers from the affected flight, as well as those booked on the return service KM515 from Vienna, were accommodated in hotels while awaiting a replacement flight.
The incident itself occurred on December 1, 2022, and was classified as a serious incident by Malta’s Air Accident Investigation authorities. At the time, the aircraft returned to Malta due to smoke in the cabin, prompting a formal investigation.
Malta’s Bureau of Air Accident Investigation (BAAI) released its final report on November 24, 2025. The investigation concluded that the probable cause of the fumes in the cockpit and forward galley—described as a pungent burnt oil odor—was a broken engine seal. Specifically, engine No. 1 suffered a failure of the bearing No. 3 seal, allowing oil to mix with the engine’s main airflow. Part of this contaminated air entered the bleed air system, passed through pack 1, and subsequently reached the cockpit and forward galley.
The BAAI noted that the same fumes and odor were also detected by cabin crew in the forward galley area extending to the over-wing emergency exit.
According to the BAAI’s sequence of events, shortly after takeoff from runway 23, both flight crew and passengers seated in the midsection of the aircraft noticed the burnt oil smell. Cabin crew in the forward section were alerted by passengers and informed the cockpit crew, who then decided to return to Malta. Rescue and Fire Fighting Services reported no signs of fire or external damage, and the aircraft taxied normally to the apron. All passengers and crew disembarked without incident and were medically assessed for possible fume inhalation, with all tests returning negative.
The final report concluded that while the incident posed a serious safety concern, the crew’s prompt response and adherence to procedures ensured a safe outcome.
