In the upgrade of the stage machinery control system for the Finnish National Opera and Ballet’s main stage, the entire solution was refined in close collaboration with the stage operators. The system controlling 250 stage-technology machines can now be operated smoothly and reliably from a single control room. Open communication and long-term cooperation were the cornerstones of the successful renewal.
In The Phantom of the Opera musical, the chandelier rises toward the ceiling as the opening notes sound, while behind the scenes of the newly renovated main stage two hoists move synchronously in different directions. The renovation of the main stage, foyer and lobby areas was completed in late summer 2023. The magical movement is powered by the upgraded stage machinery controlled by the Whisper system.
During the past summer, the main stage technology, a couple of thousand lighting fixtures, as well as the washrooms and drainage systems were renewed on a tight schedule. According to Kasperi Koimäki, Project Manager at Senate Properties, which oversaw the construction of the summer’s renovation works, the project was extremely large in relation to the time allocated for it, although the scheduling had been prepared for roughly two years. The main stage renovation was carried out as a project management service provided by A-Insinöörit, and the work related to the stage machinery control system was handled by Insta – the market leader in the field in Finland.
A major renovation in 2007 focused on ensuring operational reliability
The Finnish National Opera and Ballet reaches its 30-year milestone this year. Planning for the building began already in the 1970s, and it was opened to the public in 1993. According to Timo Tuovila, Production Director at the Finnish National Opera and Ballet, it was soon noticed after completion that changes were needed.
“Especially in theatre technology, needs were identified with regard to both the present and the future, which led to the planning of a major renovation of the main stage’s theatre technology beginning in 2004,” explains Tuovila, who is responsible for technical services, property and safety.
Tuovila says that one of the most important criteria in selecting a contractor was ensuring 100% operational reliability. The Finnish National Opera and Ballet sought a reliable partner for both the mechanical systems and the control system. Although Insta did not yet have extensive experience in theatre technology at that time, its background in demanding industrial automation projects proved convincing.
Instead of a light refurbishment, a complete overhaul was chosen. The fly system with its catwalks and hoists was dismantled and replaced with a new one. The renovation was carried out in 2007, in what Tuovila describes as perhaps the tightest schedule in the world — a one-and-a-half‑year project completed in six months.
“Even nearly 20 years later, our choice of partner has proven to be the right one,” Tuovila sums up.
Operational reliability and usability as the cornerstones of stage machinery
Stage machinery is used to move sets, performers or other elements of a production, such as overhead hoists, stage lifts or revolve stages. Automation makes it possible to move increasingly large and heavy set elements accurately and quickly. The system can be programmed with functions that would traditionally be impossible to carry out.
Because electrical systems require renewal every 15–20 years to ensure operational reliability, a new modernization of the Opera House’s main stage became timely in 2023.
“When we began working with Insta after the tendering process, the company’s slogan Worth Your Trust initially came across as just another corporate tagline, but it turned out to be a promise that truly holds. It quickly became clear that Insta would continue working with us in the 2023 renovation — not only by renewing the electrical components, but also by developing the entire stage machinery control system together with our stage operators,” Tuovila says.
The stage space was made more functional by, among other things, dismantling existing catwalks, which created room for new hoists and backdrop curtains. The orchestra lift was completely rebuilt, and its previously separate control system was integrated into the Whisper control system that operates the stage machinery. In total, around 250 stage-technology machines are connected to the control system, and the entire setup can now be operated by the main operator from a single control room.
The fourth-generation version of the Whisper control system, based on its intelligent user interface and safety automation, was released in 2021. It is built on the latest web technologies, allowing the user interface to be tailored to customer needs. With ergonomically designed wired and wireless controllers made for stage technology, creating performances is smooth and efficient.
“The renovation of Almi Hall carried out the year before last was the first of our stage machinery projects in which the new Whisper control system was delivered. At that time, it was shaped into a control system that best serves the Opera, and those learnings have been beneficial again this summer — we used every insight to upgrade Whisper into the world’s best and fully Opera‑tailored version for the main stage,” says Aleksi Nurmi, Insta’s project manager who led the renewal.
“The cornerstones of stage machinery are operational reliability and usability. We ensure reliability with a dual‑system setup as well as 24/7 phone support, remote connections and spare‑parts services. Critical components are duplicated so that the system can withstand the failure of a single component. Usability is realised through a customized control system that allows different users to operate different devices and change various parameters according to their needs. Usability is also enhanced by the controllers manufactured by Insta, which come in different versions for different purposes.
Safety features include emergency‑stop buttons, safety limits for gates and doors, limit switches, and monitoring for crushing hazards, overload and overspeed. Duplicated, monitored brakes can stop more than 125 percent overload, and mechanical limits prevent the machine from moving into areas where it could be damaged.
“These systems play a central role in productions. A single hoist malfunction can even result in a performance being cancelled and the audience sent home. The stage machinery system includes more than a hundred axes or robots that must operate reliably. The control must be flexible and fast, because every single production is a prototype,” Tuovila emphasizes.
Know‑how was transferred to users already during the project
Insta has more than 20 years of experience in stage‑technology projects. During that time, the control technology of machinery has developed significantly: hoists now operate faster and more accurately, and the industry has moved from manual or simple electrical control systems to digitally controlled stage automation and control systems developed specifically for theatres.
In the 2023 modernization, the technical challenge, according to Nurmi, was the building’s large amount of equipment, which required the development of various network solutions to ensure that the entire system functions well. Nurmi is very satisfied with the cooperation of all parties during the renewal.
“The best part of the collaboration has been the open communication and the fact that the entire staff was involved in different stages of the project. This brought great benefits, as the equipment could be built to match user preferences, and know‑how about the system was transferred to both users and the maintenance department already during the project. As a result, the commissioning has been fast and smooth,” Nurmi explains.
Tuovila also speaks warmly about working with Insta.
“We have been able to rely on Insta throughout this entire period since the 2007 renovation, when we managed to get through an extremely tight schedule together. If we have had even minor issues with the system since then, the 24/7 support has worked excellently,” Tuovila praises.
“If the rest of society has taken a digital leap in the last 20–30 years, so has theatre technology, which includes lighting, sound and video alongside stage machinery. In recent years, there have been revolutionary changes such as projections, image mapping and immersive technology — localisation and so on. One could say that only the sky is the limit. Even holograms are possible today,” Tuovila envisions.
“Another part of the future is that movement, image and sound will become increasingly integrated, meaning that systems will be combined even more closely. We have already carried out some beta tests of this together with Insta.
