Protecting Your Aviation Safety and Ensuring Compliance Following the Orion Aircraft Flare Recall

As of January 2026, Orion Safety Products has an active recall and product quarantine for specific aerial signals, which have been reported to ignite spontaneously, even when not in use. The scope is significant, affecting thousands of products used in critical safety equipment, such as aircraft survival kits and life rafts.

Affected Products

The products subject to this flare recall include the Orion Skyblazer II Red XLT Aerial Signals, also known as the Orion XLT Skyblazer self-contained red meteor flares.

Orion flares with these specs have been recalled:

• Item numbers: 769, 855/855A and 859
• Manufacturing dates: Flares manufactured between March 1, 2025, and November 24, 2025
• Expiration dates: Flares with expiration dates ranging from August 2028 through April 2029

Immediate Actions and Compliance Procedures

Your aircraft survival kits and life rafts may contain recalled Orion products, posing a risk of spontaneous combustion of the emergency flares. A clear response plan is crucial for protecting crews and passengers, preventing incidents, and maintaining compliance.

Some key steps to follow after this aircraft emergency equipment recall include:

1. Cease use immediately: Stop using any Orion Skyblazer II Red XLT Aerial Signals. These flares should be removed from all aircraft, survival kits and life rafts immediately.
2. Identify and segregate: Carefully check all existing flares for the specific product numbers and manufacturing/expiration dates. Segregate any affected flares from all other safety equipment.
3. Quarantine procedures: Store the identified recalled flares in a secure, isolated location, away from any combustible materials. It is crucial not to attempt to dispose of them yourself.
4. Plan for replacement: Begin acquiring and installing certified, compliant replacement flares. This step is essential to ensure your aircraft’s emergency equipment remains fully functional and meets all current aviation safety regulations.
5. Stay informed: Keep a close watch on official communications from Orion Safety Products, the U.S. Coast Guard and the FAA for any further updates on the recall, including details on how to return affected products and receive replacements.

Ensure Your Aviation Safety and Compliance With HRD

Ensure your aircraft’s safety and compliance today with emergency readiness. Contact HRD Aero Systems for expert assistance with your aviation safety equipment needs, from life raft flare replacement to helpful parts support. Get in touch with our FAA-licensed team for reliable service, compliant replacements and complete peace of mind.