Jetstar was forced to offload 22 passengers just before take-off for the Cook Islands to load more fuel because of threatening weather at alternate airports.
One passenger said it was an ''appalling failure'' by the airline last night whose staff read a list of passengers who wouldn't be able to board the plane.
He said those ''unlucky souls'' were told the plane about to depart from Auckland was overloaded but they could have a flight tomorrow.
The disruption caused angst for passengers as they had to re-enter customs and then hang around while confused workers attempted to make arrangements, said the passenger from flight JQ129.
''To disrupt so many passengers at the boarding gate shows a level of incompetence rarely seen in the contemporary airline industry.''