Air New Zealand has swooped in to save prime minister Christopher Luxon’s trade mission to Japan, after another one of the country’s beleaguered defence force planes was grounded in Papua New Guinea over maintenance issues.

Luxon’s high-powered business delegation was travelling to Tokyo on Sunday via Papua New Guinea, as part of the government’s mission to grow trade. However, the group – including trade minister Todd McClay, as well as dozens of business leaders and journalists – was left stranded after the discovery of blown fuses on the NZDF Boeing 757.

Luxon was able to escape the drama and maintain his schedule, by taking a last-minute commercial flight to Tokyo via Hong Kong along with three staff, but 50 others were forced into an unscheduled overnight stay in Port Moresby.

The breakdown was the second in three months, with Luxon making a similar last-minute switch to commercial flights in March to attend an Asean summit in Melbourne.

Defence minister Judith Collins explained the plane was unable to make it to Japan, but could manage a three-hour flight to Brisbane, while a re-routed Air New Zealand flight was sent to pick up the delegation.

Air New Zealand’s chief executive Greg Foran – who was among those stuck in Papua New Guinea – ordered NZ99, a direct service from Auckland to Tokyo, to make the stopover in Port Moresby to pick up the stranded delegation.

The group will reach Tokyo on Monday night.

In an interview with New Zealand media, Collins agreed the incident was “embarrassing”. It could also prove to be expensive, with the government picking up the bill for the repairs, the stopover and most likely the additional flight.

Foran told media the bill was a matter for another day, adding “let’s get everyone there. We’ll worry about what we’re going to do financially when we get everyone there.”

In recent years, NZDF planes have also failed former prime ministers Jacinda Ardern on visits to Washington and Melbourne, and delayed John Key’s 80-strong delegation to India, with a similar issue discovered on a stopover in Townsville.

There are strong debates in New Zealand as to whether it can afford to replace the planes, which are primarily used for defence business, and are seconded for use by the prime minister on trade missions.

They are due to be replaced in 2028, though a defence capability review – due this month – may recommend bringing that timeframe forward.

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