PurposeA key issue of making upgrade decisions is to match the most relevant upgrade offers to the right customers at the right time. To optimize upgrade strategies and profitability, companies seek to break “data silos” between themselves and other business partners for a more holistic view of customers' consumption experiences. However, multi-source data fusion may lead to potential privacy leakage. To overcome these two challenges in data silos and privacy protection, this study introduced a privacy-preserving federated learning (FL) approach and explained the process of using FL in modeling airline passengers’ willingness to pay for upgrade offers. Design/methodology/approachFederated learning is a new confidential computing technique that allows companies to train a model cooperatively by exchanging model parameters instead of the actual raw data, which might include customers' privacy sensitive information. Using a case study of a Chinese airline company, this study demonstrated how FL-based upgrade models using multi-source data can be developed to improve the accuracy of predicting customers' willingness to pay for upgrades while preserving customers’ personal data privacy. FindingsComparing with traditional unilateral model using single-source data, the federated logistic regression and SecureBoost models demonstrate better model performance. This indicates that the proposed FL approach can enhance the accuracy of modeling airline passengers' willingness to pay for upgrade offers while preserving passengers’ data privacy. The findings also show that the FL-based models generally took longer running time than the traditional unilateral model due to the design of FL approach in ensuring data privacy. OriginalityThis study contributes to the literature of upgrade optimization by introducing the new FL approach for developing machining learning models to predict customers’ reaction to upgrade offers. Although we focus on the airline industry in our case study, the proposed FL approach can be applied to other industries with a similar issue of upgrade optimization such as hotels or cruise lines, and car rental.