Why hot-air balloons are so expensive
Hot-air balloons have been around for centuries. They're certified aircraft for those looking to take the slow and scenic route, but owning one can set you back considerably — 30,000 euros for a smaller balloon and 150,000 euros for a larger one. At Ultramagic Balloons, half the cost is attributed to the balloon itself, known as the envelope. It can take two months to complete a safe, quality envelope. And that's just the tip of the quality-control iceberg.
Ultramagic Balloons: https://ultramagic.com/
Ultramagic Balloons: https://ultramagic.com/
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00:00 These workers are looking for any defects in the fabric of this hot air balloon,
00:07 because once it's in the air, a tear could be catastrophic.
00:12 That's why they put the fabric through this stress test.
00:17 But it's not just the balloon that needs thorough quality control.
00:23 A leak in the burner or a fault in the basket assembly can be just as dangerous.
00:29 Like a puzzle, these pieces must be aligned perfectly.
00:36 Once complete, this hot air balloon will sell for as much as 150,000 euros.
00:44 So how does over a thousand kilograms of fabric and wood float through the sky?
00:49 And why are these balloons so expensive?
00:56 Ever since the first manned hot air balloon flight in 1783,
01:01 people have been captivated by the experience it offers.
01:06 Today's manufacturers, like Ultramagic Balloons in Catalonia, Spain,
01:10 preserve this simplicity while modernising it.
01:13 It all starts with the envelope.
01:18 Hot air balloons are aircraft,
01:20 so manufacturers must carefully follow regulations set by governmental aviation agencies,
01:26 down to the fabric the balloon is made of.
01:33 Ultramagic uses specialised balloon-grade polyester and nylon fabrics
01:38 coated in silicon for their heat-resistant, antifungal and durable properties.
01:44 Workers like Mónica Morato inspect the fabric and subject it to stress tests,
01:50 ensuring that it's tear-resistant and durable.
01:56 We check the fabric and check for imperfections.
02:04 If everything is fine, we start cutting.
02:06 If there's a tear, we cut and separate it.
02:13 We continue with the process, making sure everything is in perfect condition.
02:19 Workers cut elongated strips of fabric, called gauze,
02:23 which will be sewn into the final round balloon envelope.
02:27 Standard gauze are cut by hand,
02:30 whereas the most complex shapes and design elements are done with a laser cutting machine.
02:36 Just cutting the envelope pieces can take a week.
02:45 The pattern is more difficult because it's a puzzle,
02:50 but here we sew it with a funnel.
02:56 Consuelo has been working as a seamstress at Ultramagic for 37 years.
03:02 She's one of 20.
03:06 She sews the gauze together over pieces of load tape.
03:11 These are durable, seatbelt-like strips that help carry the weight of the hot air balloon
03:16 and prevent strain on the fabric.
03:20 Consuelo's experience sewing the balloons makes her invaluable.
03:26 Adriana Yadó, an engineer at Ultramagic and one of the daughters of the founder,
03:31 says sewing is the skill that has the biggest effect on quality.
03:36 The most difficult part in the process is sewing the envelope,
03:40 and it's basically because the fabric is very difficult to work with
03:44 and it takes two years for a seamstress to build a complete hot air balloon by herself.
03:51 The envelope alone accounts for 50% of the cost,
03:55 and the larger the balloon, the more fabric required, so the more expensive it is.
04:01 Envelopes for the smallest three-person balloons can take two weeks to make,
04:06 with the final balloon cost at €30,000.
04:11 But Ultramagic's largest balloon envelopes require up to two months of work.
04:16 They can hold 29 people and cost €150,000.
04:23 Custom design requests will bump the price up higher.
04:28 While Consuelo constructs the envelope, engineers work on another essential component,
04:34 the burner system.
04:40 Smaller balloons require two burners, while larger ones need four.
04:46 Ultramagic subcontracts its burner designs, but assembles the parts in-house.
04:52 Most hot air balloons use liquid propane,
04:55 which travels through superheated coils that vaporise it.
05:01 A pilot light ignites the gas and the flame heats the air inside the balloon.
05:07 This hot air is lighter than the colder air outside the balloon, lifting it.
05:12 Engineers carefully wrap the coils in a spiral and connect it to the fuel tank.
05:18 Each piece is assembled like a puzzle, but with the plans we have, we assemble it.
05:27 This is the serpentine part, which is the last thing we put on once the mechanism is assembled.
05:36 Then we put the hoses, which are like this, to test the gas.
05:49 They test for gas leaks by spraying soapy water, lighting the burner and inspecting for any bubbles.
05:57 They also check for any debris that may hinder the burner's functionality.
06:03 Just as with the envelope, any defects here could risk the burner failing and the balloon falling from the sky.
06:14 Meanwhile, Samuel Agustin and his team hand-weave the baskets that passengers will ride in.
06:23 Samuel has been weaving for Ultramagic for 16 years.
06:27 He says building a basket requires careful teamwork.
06:33 Usually we work in pairs, one person inside and one outside.
06:40 If it's a basket like this, which is a C14, from start to finish, it takes about a month and three weeks.
06:54 But if we do it between four people, maybe we can finish in a month.
06:59 Ultramagic constructs its baskets out of rattan.
07:04 It's not an aesthetic choice, but a practical one.
07:09 Rattan is not only flexible and durable, it absorbs any shock from a bumpy landing, protecting the passengers inside.
07:19 The cables are much more important. Any failure is not allowed to fly.
07:28 These cables are woven into the wicker basket and are eventually connected to the envelope, helping to support the weight of the basket.
07:38 According to Ultramagic, the rattan materials, as well as the time it takes to construct the baskets properly, account for 30% of a balloon's cost.
07:50 When the sewing, engineering and weaving departments have finally completed their work, the puzzle pieces of the hot air balloon are ready to be put together.
08:01 The basket is connected to a metal frame that also supports the burner system.
08:07 Steel cables are connected to the envelope through carabiners, joining all the elements of the hot air balloon.
08:15 Then it's time to inspect the balloon.
08:20 A team inflates the 7.3-metre envelope to check for leaks.
08:26 They inspect every inch of rope, cable and fabric for any defects that may have been missed in production.
08:35 If everything's up to par, the basket is flipped upright, the burners are lit and the balloon is ready to fly.
08:49 Ultramagic is seeing demand rise, especially in countries with increasing tourism.
08:56 The company sells its hot air balloons to individual buyers, as well as companies looking to offer commercial balloon rides.
09:06 It's a team of almost 70, making about 100 hot air balloons a year.
09:12 But the company says meeting the growing demand is challenging.
09:17 It takes time to train its employees in such niche skill sets, so expanding too quickly can come at the expense of quality.
09:28 Even as the global hot air balloon market is expected to, well, balloon to $11.5 billion by 2027.
09:38 [Music]