Industry Overview
Solar photovoltaic (PV) modules are packaged assemblies of solar cells designed to convert sunlight into electricity for residential, commercial, industrial, and other applications. A typical PV module consists of interconnected solar cells and incorporates components such as glass, EVA film, a back sheet, an aluminium frame, a junction box, bypass diodes, connecting ribbons, and cables. Modules are rated according to their DC output power under standard test conditions.
A complete photovoltaic system generally comprises one or more solar modules, a solar inverter, interconnection wiring, and, depending on the application, battery storage or a solar tracker. The report covers the construction, specifications, types, fabrication process, applications, plant and machinery, market position, manufacturing opportunities, plant layout, and suppliers associated with solar PV modules. It discusses crystalline silicon technologies, including monocrystalline and polycrystalline modules, as well as their respective advantages, disadvantages, and applications. The report also examines opportunities in the Indian and global solar module segments, bifacial module trends, supply-demand considerations, and supporting infrastructure required for PV module manufacturing.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 34 KW/Day |
| Land & Building (4000 sq.mt.) | Rs. 5.38 Cr |
| Plant & Machinery | Rs. 2.63 Cr |
| Working Capital for 2 Months | Rs. 3.36 Cr |
| Total Capital Investment | Rs. 11.77 Cr |
| Rate of Return | 33% |
| Break Even Point | 57% |
Content Index
- INTRODUCTION
- SOLAR PHOTO VOLTAIC (SPV) MODULE
- CONSTRUCTION OF PV MODULE
- PV CELLS
- A MONOCRYSTALLINE SOLAR CELL
- GLASS
- FRAME
- EVA FILM
- BACK SHEET
- JUNCTION BOX
- BYPASS DIODES
- NUMBER OF CELLS IN MODULE
- SOLAR PV MODULE SPECIFICATION
- (A) MECHANICAL SPECIFICATION
- (B) ELECTRICAL SPECIFICATION
- TYPES OF SOLAR 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
- 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)
- PLANT AND MACHINERY
- (1) CELL TESTER
- (2) TABBING & STRINGING MACHINE
- (3) LAYUP MACHINE
- (4) MODULE LAMINATOR
- (5) MODULE TESTER
- (6) LASER INSPECTION MACHINE
- MARKET POSITION/OVERVIEW
- INDIA – POTENTIAL
- ANNUAL INSOLATION
- OPPORTUNITIES IN THE INDIAN SOLAR MODULE SEGMENT
- OPPORTUNITIES IN THE GLOBAL SOLAR MODULE SEGMENT
- DEMAND FOR SOLAR PV MODULES BY YEAR (GW)
- INDIA HAS A CHANCE TO BE LEADER PV MODULE MANUFACTURING BY 2020
- WHY SHOULD WE PRODUCE PV MODULES IN INDIA?
- DOES IT MAKE ECONOMIC SENSE TO SET UP PV MODULE CAPACITY IN INDIA?
- WHAT IS A REALISTIC INDIAN SOLAR ENERGY INSTALLATION TARGET BY 2022?
- WHAT GREENTECH MEDIA SAYS ABOUT INDIA’S ATTRACTIVENESS IN PV MODULE MANUFACTURING?
- HOW BIG IS THIS OPPORTUNITY?
- WHEN CAN INDIA BE A LEADER IN PV MODULE MANUFACTURING?
- SOLAR INDUSTRY WISHES BIG GROWTH NEXT YEAR
- WE RECOMMEND
- MORE FROM THE AUTHOR
- INDIA SOLAR PHOTOVOLTAIC MARKET OUTLOOK, 2022
- FUTURE GROWTH OF SOLAR IN INDIA
- MODULE EXPORT DATA
- BIFACIAL MODULE EXPORT 2018
- TRENDS
- MAJOR CONSTRAINT
- BIFACIAL TECHNOLOGY TRENDS
- SUPPLY-DEMAND FORECAST OF BIFACIAL MODULES
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF SOLAR PV MODULE
- SUPPLIERS OF RAW MATERIAL FOR SOLAR PV MODULE
- 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
- SUPPLIERS OF PLANT AND MACHINERY FOR SOLAR PV MODULE
- SUPPLIERS OF COMPELETE PRODUCTION PLANT FOR PV PANNEL
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
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
A solar photovoltaic module is a packaged assembly of interconnected solar cells that converts sunlight directly into electricity. A module generally incorporates solar cells along with glass, EVA encapsulant, a back sheet, frame, junction box, bypass diodes, and connecting components. Multiple modules can be connected to form a larger solar array. PV modules are used in residential, commercial, industrial, agricultural, telecommunications, public-service, and other applications where solar electricity is required.
The main components of a solar PV module include solar cells, glass, EVA film, a back sheet, an aluminium frame, a junction box, bypass diodes, connecting ribbons, cables, and sealants. Each component contributes to the electrical performance, mechanical strength, weather protection, insulation, or long-term reliability of the module. The report also discusses the requirements associated with these components as part of the module fabrication process.
Monocrystalline and polycrystalline PV modules use crystalline silicon solar cells but differ in cell manufacturing and crystal structure. Monocrystalline cells are produced from single-crystal silicon, while polycrystalline cells are made from multiple silicon crystal structures. These differences influence characteristics such as appearance, manufacturing process, efficiency, space requirements, and cost. The report covers the construction, technical specifications, advantages, disadvantages, and applications of both module types.
Solar PV module manufacturing requires equipment for cell testing, interconnection, layup, lamination, inspection, and final module testing. The report identifies a cell tester, tabbing and stringing machine, layup machine, module laminator, module tester, and laser inspection machine among the principal machinery. The exact equipment configuration depends on the module technology, production process, automation level, quality requirements, and desired manufacturing capacity.
The solar PV module manufacturing process involves preparing and interconnecting solar cells and assembling them with protective and structural components. Typical stages include cell preparation and testing, tabbing and stringing, arranging the cell strings with EVA and other layers, layup, lamination, framing, installation of the junction box and cables, sealing, inspection, and electrical testing. The report provides a detailed fabrication process covering solar cells, EVA, back sheet, glass, junction box, connecting ribbons, silicone sealant, and module frames.
Solar PV modules are used across residential, agricultural, industrial, telecommunications, public-service, and healthcare applications. They can form part of rooftop systems, ground-mounted solar installations, remote power systems, and other photovoltaic power plants. The report specifically identifies agriculture, industry, telecommunications and public services, health, and residential applications. PV modules can also be integrated with inverters, wiring, battery storage, and other system components depending on the intended application.
Setting up a solar PV module manufacturing plant requires consideration of production technology, raw material supply, machinery, quality requirements, plant layout, utilities, testing facilities, manpower, and market access. Reliable supplies of solar cells, EVA encapsulant, tempered glass, aluminium frames, junction boxes, back sheets, sealants, and other components are important. The report also addresses supporting equipment and infrastructure, supplier categories, manufacturing opportunities in India and globally, market trends, and supply-demand considerations.
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