Trailblazing aluminium shipbuilding in India

In an industry dominated by steel and legacy ship designs, Goa-based Synergy Shipbuilders N Dock Works Ltd. Has emerged as a pioneer of aluminium vessel construction in India. With over 100 vessels built across multiple segments and a forward-thinking approach to propulsion, design, and sustainability, the company is quietly but firmly steering Indian shipbuilding into the future.

Siddarth, how did Synergy Shipbuilders come into being,and how has the journey evolved over the years?

Synergy Shipbuilders was established in 1988 by my father, Shriram Malik, a marine engineer who graduated from DMET in 1967. After spending years working offshore, he returned to Goa with the intent of contributing to India’s maritime ecosystem.

Back then, Goa had only a handful of small yards, and he saw an opportunity to create a facility that could serve the regional need for coastal vessels–especially for iron ore movement, which was a key commodity in the region at the time.

From those humble beginnings, Synergy Shipbuilders gradually grew into a trusted builder of small and medium-sized vessels. I joined the company in 2004 after completing my engineering degree in the UK, and I officially took over the reins in 2017. Under my father’s vision and later through our collective efforts, we have built and delivered over 100 vessels across multiple segments–ranging from general cargo ships to offshore support vessels like anchor handling tugs and crew boats. What makes this journey unique is not just the diversity of vessels we’ve built, but the way we’ve consistently adapted to changes in technology, regulations, and customer expectations. In 2013, we diversified into aluminium shipbuilding, which has since become our forte. That pivot truly set us apart in the Indian shipbuilding ecosystem.

Your foray into aluminium shipbuilding has drawn considerable industry attention. Tell us more about that strategic pivot.

Yes, it was indeed a defining moment for us. In 2013, we took a strategic decision to diversify into aluminium construction–a material that requires a very different approach compared to steel. At that time, there were very few shipyards in India, especially in the private sector, that had the capabilities or confidence to build large aluminium vessels.

We were fortunate to be awarded contracts for two 40-meter high-speed aluminium boats, one of which was for ADNOC (Abu Dhabi National Oil Company). These vessels required not only speed and precision in construction but also global-class safety and design standards. We had to invest heavily in retraining our workforce, setting up dedicated fabrication bays, and upgrading welding certifications in compliance with international class societies.

Delivering those vessels successfully was a major achievement–it established us as pioneers in aluminium vessel construction in India. Since then, we’ve gone on to build several aluminium boats, especially for defence, paramilitary, and offshore clients. These include patrol craft, crew transfer vessels, pilot boats, and fast utility boats.

What kind of vessels and services form your current core offering?

We offer a full range of services from design to delivery, primarily focusing on vessels up to 110 meters length for steel and alumnium. While our earlier years focused heavily on cargo vessels and tugs, today we are increasingly catering to high-performance, fast-response, and custom-built boats. This includes crew boats for offshore energy, interceptor boats for maritime security agencies, and support vessels for renewable energy projects such as offshore wind.

We’re also building two passenger ferries–one for the Andaman administration with 390-passenger capacity, and another for Zanzibar, a 53-meter high-speed aluminium catamaran.

We won the Zanzibar contract over two established Chinese yards, which reinforces our global competitiveness. Our latest milestone is India’s first 29-meter high-speed aluminium crew boat built under IR class and DG Shipping flag. It’s now operating for ONGC in Bombay High. That success has led to repeat orders from multiple clients.

How are you aligning with the broader push for green shipping and sustainable technologies?

Sustainability is no longer an option–it’s a necessity. We recognise this and are actively exploring pathways to make our vessels more energy-efficient and environmentally friendly. Aluminium, by its nature, contributes to fuel efficiency due to its lightweight properties. But we’re going beyond that. We’ve begun exploring hybrid and electric propulsion systems for smaller vessels. There’s a growing interest among ports, pilotage services, and coastal surveillance agencies for green propulsion.

We’re also incorporating hull form optimisation in our designs to reduce resistance and fuel burn. In addition, we’re working with suppliers to integrate solar-assisted systems and low-emission auxiliary units on board. Though the market in India is still maturing, we believe that early adoption will place us ahead of the curve once regulatory mandates and ESG compliance norms begin tightening across the board.

What are the major challenges you face, particularly with aluminium shipbuilding in India?

The biggest challenge is sourcing aluminium. Marine-grade aluminium isn’t manufactured at scale in India. Even Hindalco, which recently started production, offers limited grades and thicknesses. As a result, we rely on imports–mainly from Europe and the Far East.

However, regulatory hurdles like BIS certification and antidumping duties (ADD) on Chinese aluminium make this difficult. It’s paradoxical–when a product isn’t manufactured locally, imposing such barriers hurts domestic builders. Leading European producers like Elval have declined BIS registration, citing low volumes and high compliance costs for Indian exports.

Beyond material supply, we also face logistical delays, permissions and approvals, and limited design innovation within the country.

What about ship design capabilities and skilled manpower? Are those adequate in India today?

On the manpower side, we’re in a good place. Our teams are young, highly trained, and committed. Design, however, remains a bottleneck. Most Indian design houses are following legacy concepts. There is resistance to innovation and hesitance for adapting to new vessel forms or propulsion layouts. Hence, we often rely on European or Singaporean naval architects who are progressive and open to experimentation. We need more homegrown design innovation to match global standards.

What’s next for Synergy?

Looking ahead, our focus is on scaling aluminium shipbuilding at our two facilities–Goa and our new yard in Mumbai. The Mumbai yard, being developed in three phases, will soon have a ship lift and eventually a graving dock. We aim to make it a state-of-the-art centre for aluminium vessel construction.

We’re also eyeing export opportunities across Africa, the Middle East, and Southeast Asia. Our goal is to make Synergy Shipbuilders synonymous with world-class aluminium ships–designed, built, and flagged in India.