Code #3980
Industry Overview
Photovoltaic solar cells are thin silicon disks that convert sunlight into electricity and serve as efficient energy sources for applications including calculators, telecommunications devices, pumping, lighting, refrigeration, rooftop panels, power satellites, power plants, and other electrical uses. Solar module manufacturing involves arranging and electrically interconnecting solar cells, encapsulating them with ethylene vinyl acetate (EVA), and assembling them with a glass front, Mylar backsheet, aluminum frame, and silicone sealing. Lamination is a critical stage in forming and protecting the module structure.
Quality control and electrical testing are essential throughout solar cell and module production. Flash testing is used to measure parameters including open-circuit voltage (VOC), current and voltage at maximum power point, short-circuit current, fill factor (FF), and maximum power under standard testing conditions. Silicon and finished cells are inspected for purity, resistivity, crystal orientation, oxygen and carbon content, surface damage, bending, polishing, sawing, and etching. Manufacturing parameters such as temperature, pressure, speed, and dopant quantities require close monitoring. Finished modules undergo testing and field-site evaluation to assess performance under ambient operating conditions and support reliable, efficient operation.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 0.76 MW/Day |
| Land & Building (12000 sq.mt.) | Rs. 14.47 Cr |
| Plant & Machinery | Rs. 30.45 Cr |
| Working Capital for 1 Month | Rs. 34.96 Cr |
| Total Capital Investment | Rs. 80.60 Cr |
| Rate of Return | 68% |
| Break Even Point | 27% |
Content Index
- INTRODUCTION
- CELLS MODULES AND ARRAYS
- PHOTOVOLTAIC CELLS, MODULES, PANELS AND ARRAYS.
- PHOTOVOLTAIC CELL
- PHOTOVOLTAIC MODULES
- SINGLE CRYSTALLINE
- POLYCRYSTALLINE OR MULTICRYSTALLINE
- STRING RIBBON
- AMORPHOUS OR THIN FILM
- PHOTOVOLTAIC PANELS
- PHOTOVOLTAIC ARRAY
- PROJECT LOCATION-SURAT (GUJRAT)
- CITY MAP OF SURAT
- WEATHER
- TRANSPORTATION
- HISTORY OF PHOTOVOLTIC CELLS
- TYPES OF PV MODULE
- CRYSTALLINE SILICON PV MODULE
- (I) SINGLE CRYSTALINE (MONO-CRYSTALLINE)
- CONSTRUCTION
- TECHNICAL SPECIFICATION
- ADVANTAGES OF MONOCRYSTALLINE PV MODULE
- DISADVANTAGES
- APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
- (II) POLY-CRYSTALLINE (MULTI CRYSTALLINE)
- CONSTRUCTION
- ADVANTAGES OF POLYCRYSTALLINE PV MODULE
- DISADVANTAGES OF POLYCRYSTALLINE SOLAR PANELS
- CONSTRUCTION OF PV MODULE
- THE 6 MAIN COMPONENTS OF A SOLAR PANEL
- PV CELLS
- A MONOCRYSTALLINE SOLAR CELL
- GLASS
- FRAME
- EVA FILM
- BACK SHEET
- JUNCTION BOX
- BYPASS DIODES
- NUMBER OF CELLS IN MODULE
- PROS & CONS OF PV
- COMPLETE PHOTOVOLTAIC-BASED ELECTRICAL SYSTEMS:
- CONFIGURED SOLAR ELECTRIC SYSTEMS
- PHOTOVOLTAIC MODULE PERFORMANCE
- PHOTOVOLTAIC APPLICATIONS
- PHOTOVOLTAIC BENEFITS
- SOLAR CELL I-V CHARACTERISTIC
- SOLAR CELL I-V CHARACTERISTIC AND THE SOLAR CELL I-V CURVE
- SOLAR CELL I-V CHARACTERISTIC CURVE
- THE ELECTRICAL CHARACTERISTICS OF A PHOTOVOLTAIC ARRAY
- SOLAR ARRAY PARAMETERS
- EXAMPLE OF I-V CURVE AND RATINGS OF A 12 V SOLAR (PV) PANEL
- FIG.. EXAMPLE OF I-V CURVE AND RATINGS OF A 12 V PV / SOLAR PANEL
- IV CURVE
- IDEAL SOLAR CELL
- IDEAL SOLAR CELL (SIMPLIFIED)
- EFFECT OF TEMPERATURE
- THE AFFECTS OF IRRADIANCE
- FIGURE :- PV CELL POWER OUTPUT AS A FUNCTION OF VOLTAGE.
- EFFECT OF LIGHT INTENSITY
- CONCENTRATORS
- LOW LIGHT INTENSITY
- LINE CAPACITY
- TABBER AND STRINGERS:
- LAY-UP:
- INTERCONNECTION
- LAMINATORS:
- SOLAR PV MODULE SPECIFICATION
- (A) MECHANICAL SPECIFICATION
- (B) ELECTRICAL SPECIFICATION
- DIFFERENCE BETWEEN STC AND NOCT:
- STC (STANDARD TEST CONDITIONS):
- APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
- ADVANTAGES OF PV PANNEL
- DISADVANTAGES OF PV PANNEL
- USES AND APPLICATION OF PV POWER PLANT
- APPLICATIONS OF MONOCRYSTALLINE SOLAR PANELS
- APPLICATIONS OF POLYCRYSTALLINE SOLAR PANELS
- EXAMPLES OF SOME APPLICATIONS OF PHOTOVOLTAICS ARE THE FOLLOWING:
- AGRICULTURE
- INDUSTRY, TELECOMMUNICATIONS & PUBLIC SERVICES
- HEALTH
- RESIDENTIAL
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART FOR SOLAR PANEL
- FABRICATION PROCESS
- OF MONOCRYSTALLINE SOLAR PV MODULE
- A. SOLAR CELL
- B. EVA (ETHYLENE VINYL ACETATE)
- ENCAPSULANT’S (EVA) REQUIREMENTS:
- C. BACKSHEET
- REQUIREMENTS OF REAR SURFACE:
- D. GLASS
- REQUIREMENTS:-
- E. JUNCTION BOX WITH BYPASS DIODES AND CONNECTING CABLES JUNCTION
- CABLES JUNCTION BOX CONSISTS OF THE FOLLOWING:-
- F. CONNECTING RIBBON TWO TYPES OF CONNECTING RIBBON ARE
- G. SILICONE SEALANT
- SEALANT
- H. SHORT AND LONG FRAMES (BACKBONE OF THE MODULE STRUCTURE)
- MARKET POSITION
- PV MODULES MARKET – INDIA
- RISING IMPORTS:
- DOMESTIC INDUSTRY WOES
- WAY FORWARD
- RISEN ENERGY
- WAAREE
- ZNSHINE
- VIKRAM SOLAR
- ADANI
- TRINA SOLAR
- RENESOLA
- JINKOSOLAR
- LONGI SOLAR
- CANADIAN SOLAR
- GLOBAL MARKET
- TECHNOLOGY INSIGHTS
- APPLICATION INSIGHTS
- GRID TYPE INSIGHTS
- REGIONAL INSIGHTS
- KEY COMPANIES & MARKET SHARE INSIGHTS
- PV PRODUCTION LINE
- M-01 AUTOMATIC GLASS LOADING
- M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING
- M-03 AUTOMATIC TEMPLATE LOADING
- M-04 INSPECTION TABLE
- M-05 TABBER AND STRINGER MTS-3000
- M-06 LAY-UP SYSTEM
- M-07 MIRROR INSPECTION TABLE
- M-08 AUTOMATIC BUSSING IC100 (3 HEADS
- M-09 INTERCONNECTION CHECKING + LABEL PLACING
- M-10 EL INSPECTION
- M-11 AUTOMATIC FOIL CUTTING AND LOADING
- M-12 BUFFER
- M-13 LAMINATOR
- M-14 AUTOMATIC EDGE TRIMMING
- M-15 AUTOMATIC OPTICAL INSPECTION
- M-16 AUTOMATIC FRAMING UNIT
- AUTO FRAME FEEDER (OPTIONAL):
- M-17 JBOX WORKING TABLES
- M-18 AUTOMATIC JBOX POTTING MACHINE
- M-19 JBOX POTTING DISPENSING MACHINE
- M-20 JBOX SILICONE DISPENSING MACHINE
- M-21 CURING LINE
- M-22 MODULE TESTING STATION
- M-23 AUTOMATIC MODULE SORTING
- M-24 AUTOMATIC GLASS LOADING
- M-25 SECOND GLASS LOADING
- M-26 AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
- M-27 AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
- ACCESSORIES
- A-01 CELL TESTER
- ASSEMBLY LAYOUT
- LINE LAYOUT (PROPOSED)
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF SOLAR PV MODULE
- RAW MATERIAL
- SUPPLIERS OF SOLAR CELL
- SUPPLIERS OF EVA ENCAPSULATE
- SUPPLIERS OF TEMPERED GLASS
- SUPPLIERS OF ALUMINIUM FRAMER
- SUPPLIERS OF JUNCTION BOX
- SUPPLIERS OF SILICON GEL
- SUPPLIERS OF THERMO PLASTIC BACK SHEET
- MACHINERY SUPPLIERS
- COMPELETE PRODUCTION PLANT
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
- MACHINERY PHOTOGRAPHS
- AUTOMATIC GLASS LOADING
- AUTOMATIC ENCAPSULANT CUTTING AND LOADING
- AUTOMATIC TEMPLATE LOADING
- INSPECTION TABLE
- TABBER AND STRINGER MTS-3000
- MIRROR INSPECTION TABLE
- AUTOMATIC BUSSING IC100 (3 HEADS)
- INTERCONNECTION CHECKING + LABEL PLACING
- AUTOMATIC FOIL CUTTING AND LOADING
- BUFFER
- LAMINATOR
- AUTOMATIC EDGE TRIMMING
- AUTOMATIC OPTICAL INSPECTION
- AUTOMATIC FRAMING UNIT
- JBOX WORKING TABLES
- JBOX POTTING DISPENSING MACHINE
- JBOX SILICONE DISPENSING MACHINE
- CURING LINE
- MODULE TESTING STATION
- AUTOMATIC MODULE SORTING
- AUTOMATIC GLASS LOADING
- AUTOMATIC MODULE SORTING FOR GG (INSTEAD OF M-23)
- AUTO CELL LASER CUTTING MACHINE (OPTIONAL)
- CELL TESTER
- PRODUCT PHOTOGRAPHS
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Solar PV module manufacturing involves arranging and electrically interconnecting solar cells before encapsulating and assembling them into a protected module. The cells are wired and arrayed, sealed with EVA, combined with a glass front and backsheet, framed with aluminum, and sealed using silicone. Lamination is a critical manufacturing stage because it integrates the module layers into a durable structure. The completed module is subsequently subjected to electrical and quality-control testing before field-site evaluation.
The main solar panel components covered in the report include PV cells, glass, frame, EVA film, back sheet, junction box, and bypass diodes. Connecting ribbons, silicone sealant, and associated framing components are also important in module construction. These components work together to provide electrical functionality, mechanical support, environmental protection, and reliable interconnection. The report also discusses module construction, the number of cells in a module, and the specifications associated with photovoltaic modules.
Lamination is important because it forms the integrated layered structure of the solar module and helps protect the internal components. In the reported process, solar cells are encapsulated in EVA and assembled between the front glass and rear backsheet before the structure is laminated. This stage is identified as one of the most important steps in solar module manufacturing. Proper processing contributes to the mechanical integrity and protection of the finished module while supporting reliable operation in service.
Solar PV modules undergo electrical testing to verify their power output and operating characteristics. The report specifically identifies flash testing, which measures open-circuit voltage (VOC), current at maximum power point, short-circuit current, voltage at maximum power point (VMP), fill factor (FF), and maximum power. Measurements are made under standard testing conditions. Additional inspection and electrical tests are used during manufacturing to maintain appropriate standards for current, voltage, resistance, and overall module quality.
Standard testing conditions are controlled reference conditions used to measure photovoltaic module performance. The report describes them in relation to the irradiance and sunlight spectrum corresponding to sunlight incident on a clear day with the sun at a specified angle above the horizon. STC provides a consistent basis for evaluating electrical parameters such as voltage, current, fill factor, and maximum power. The report also includes a section comparing STC and NOCT in the context of solar PV module specifications.
A solar PV module production line can include equipment for glass loading, encapsulant cutting and loading, template loading, inspection, tabbing and stringing, lay-up, bussing, interconnection checking, EL inspection, foil handling, lamination, edge trimming, optical inspection, framing, junction-box processing, curing, testing, and module sorting. The report lists specific production-line equipment from M-01 through M-27, along with accessories such as a cell tester. It also covers proposed line layouts, plant layouts, machinery photographs, and machinery suppliers.
Solar cell performance can be affected by material quality, manufacturing conditions, temperature, irradiance, and light intensity. The report emphasizes inspecting silicon for crystal orientation, resistivity, purity, oxygen and carbon content, and physical defects. Manufacturing parameters such as temperature, pressure, speed, and dopant quantities also require monitoring. It further discusses the effects of temperature, irradiance, and light intensity on photovoltaic output, together with I-V characteristics and the electrical characteristics of photovoltaic arrays.
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