The international maritime industry group Inocea is building a strong shipyard presence in Finland, consisting of Sata Shipbuilding Oy in Pori and Helsinki Shipyard. Close cooperation between the companies brings together international opportunities and domestic resources under one roof to meet growing demand for demanding special-purpose vessels.
This setup is now being strengthened by a major production investment: the Pori shipyard has commissioned a new MicroStep MG bevel plasma cutting system, improving production efficiency, weld preparation, and throughput times.
Sata Shipbuilding Oy is a Finnish shipyard operator whose role within Inocea’s operations in Finland focuses especially on the manufacturing of icebreakers, as well as special-purpose, offshore, and government vessels. Together with Helsinki Shipyard, the company forms a technically versatile production environment combining expertise in heavy steel construction, project management, and flexible production capacity.
This supports the group’s strategy of growing its presence in Europe and responding to market demand. The Finnish shipyards provide a competitive operating environment, particularly for high value-added projects where quality, delivery reliability, and technical expertise are essential.
Sata Shipbuilding’s key strengths include flexible production resources, the ability to scale work project by project, and a strong subcontractor network. The company uses modern production methods and is responsible for the manufacture of demanding steel structures as well as vessel lifecycle services.
Together with Helsinki Shipyard, the overall setup gives the Inocea Group capacity for new vessel construction. This makes it possible to execute several projects simultaneously and shorten lead times for customers.
Inocea group companies Davie Shipbuilding, Gulf Copper, and Federal Fleet already have a strong foothold in North America. Expanding operations into Finland strengthens the company’s position as a global player. The Finnish units play a key role especially in projects intended for the European market.
After processing on the new MicroStep, parts are transferred in a largely finished state directly from the cutting table to welding without the need for grinding. The machine also includes a punch-marking system tailored to the shipyard’s needs, allowing required information to be permanently marked on plates.
Outdated equipment drove the investment
The investment in the new bevel plasma cutting system, the MicroStep MG25501.35PrkM, was driven above all by production needs. “Our old machine was from the early 2000s and technically outdated, and it no longer met current requirements,” says Fabrication Lead Jukka Kukkumäki.
This was not merely a replacement investment, but also a clear technological leap forward. The MicroStep bevel plasma cutting system was customized for Sata Shipbuilding Oy’s needs, including a massive table size of 3.5 x 25 meters, allowing two full-length 12-meter plates to fit on the table one after the other. The machine is powered by Hypertherm’s most powerful XPR460 power source.
The machine was also customized with a punch-marking system suited to the shipyard’s needs, enabling required information to be permanently marked onto the plates.
Plasma technology meets the shipyard’s needs
When selecting the technology for the machine investment, laser was quickly ruled out. “Laser is not a sensible solution for us. We cut a lot of thick plates, in practice up to 50 mm, and plasma works better in that range.”
In addition, the shipyard environment influenced the choice. “The plates are not always completely clean. Laser requires a clean surface, but plasma tolerates practical operating conditions better.”
Plasma was seen as a more efficient overall solution for shipyard production, especially when processing thicker materials.
Cooperation played a decisive role
MicroStep became part of Sata Shipbuilding Oy’s production equipment at the beginning of April, and after the ramp-up phase, full-scale production began in mid-May. The delivery project progressed according to plan.
“Discussion was smooth from the very beginning with Machinery MT, the supplier of the MicroStep system, and the cooperation worked well. Commissioning went smoothly, and contact with the supplier has remained close. In practice, everything went as agreed from the beginning to the end of the project,” Kukkumäki says.
Local support was an important factor: “Spare parts and service are nearby, which was important for us. Post-commissioning support is also essential. If help is needed, it has to be available quickly, and remote support must work well.”
“Our decision was also influenced by the fact that MicroStep machines are widely used in the shipbuilding industry,” emphasizes Production Director Tomi Nyroos.
“From the machine supplier’s point of view, the smooth implementation of the project was greatly helped by the customer’s strong experience with plasma machines. Discussions are good when there is a common language and shared intent,” says Petri Halme of Machinery MT.
The MicroStep MG25501.35PrkM was customized to Sata Shipbuilding Oy’s needs, including the massive 3.5 x 25 meter table, which can hold two full-length 12-meter plates in sequence.
MicroStep stood out as a complete solution
The bevel plasma system was selected from among four different machine brands. Performance and practical usability were the key factors. “The complete package was decisive. The machine’s robust frame, capability, bevel-cutting performance, and suitability for our use were key factors. The most essential components were MicroStep’s bevel head and the heavy-duty power source,” Kukkumäki summarizes.
The solution was seen as supporting production as a whole. “The machine must function well as part of our production and planning. Software is an important element in the renewal of our production process, where MicroStep’s software will be integrated as part of the overall production system,” Kukkumäki explains.
Less finishing work, faster throughput
According to Nyroos, the benefits of MicroStep are directly visible in production: “MicroStep’s quality performance is high, and it is faster than our old machine. We now get more finished parts directly from the plasma process. Previously, they needed more work after plasma cutting; now the parts come largely finished, without the need for grinding, straight from the cutting table to welding. This speeds up throughput times and therefore the entire production chain.”
In shipyard use, capacity and size are critical
In the shipbuilding industry, the machine must be able to process large and heavy parts.
“Plasma cutting plays a central role for us. The machine must be able to handle large assemblies. The new MicroStep meets this need well and supports the entire production process. Fit-up is better, and the whole setup fits production better,” Kukkumäki says.
Lifecycle and costs under control
Lifecycle costs were also considered in the investment. “Long-term costs and operational reliability are important to us. That is why we took out a service agreement for the MicroStep system with Machinery MT. When the full package service agreement, training, and remote support come from Machinery MT, it creates security and confidence in our operations.”
Shortage of skilled workers remains a challenge
Around 250 people work at the Pori unit. According to Kukkumäki, there is currently plenty of work and the outlook is also quite positive. The company’s growth is challenged by the availability of skilled labor. “We are constantly looking for new talent. It is a major challenge, and we are working hard on it through our own training projects, among other things,” Kukkumäki says.
A versatile role in the shipyard group
Sata Shipbuilding operates as a key part of the group’s Finnish presence. The company’s role is especially emphasized in demanding projects that combine design, manufacturing, and project management. “There are not many specialists like us in the world, for example in the construction of icebreakers. It is also worth remembering that these products are not only manufactured in Finland, but also largely designed in Finland,” Nyroos concludes.
MicroStep – a producer of CNC cutting machines for plasma, laser, oxyfuel, waterjet cutting and routing. Complex processing of sheets, pipes, profiles and domes. Bevel cutting, milling, drilling, tapping, marking, bending, welding. Automated solutions. CNC control systems and CAM. CAPP applications for complex production management.
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