Industry Overview
Photovoltaic solar cells are thin silicon-based devices that convert sunlight directly into electricity and serve a wide range of applications, including calculators, telecommunication equipment, water pumping, lighting, refrigeration, rooftop solar systems, power satellites, power plants, and other electrical systems. Solar module manufacturing involves assembling photovoltaic cells, establishing electrical contacts, wiring and arranging the cells, encapsulating them with ethylene vinyl acetate (EVA), and completing the structure with glass, a backsheet, aluminium framing, and silicon sealant.
Lamination is a critical stage because it protects the assembled cells and contributes to the durability of the finished module. Following assembly, modules undergo electrical and performance testing, including flash testing to measure open-circuit voltage (VOC), short-circuit current, voltage and current at maximum power point, fill factor (FF), and maximum power under standard testing conditions.
Quality control is essential throughout photovoltaic manufacturing because variations in material properties and processing conditions can affect cell efficiency and service life. Silicon is evaluated for crystal orientation, resistivity, purity, oxygen and carbon content, while wafers are inspected for bending, flaking, damage, polishing, sawing, etching, and other defects. Manufacturing parameters such as temperature, pressure, speed, and dopant quantities are carefully monitored. Electrical testing verifies current, voltage, and resistance requirements, while shunt diodes help protect cells against undesirable high-voltage conditions. Final field testing evaluates module performance under actual ambient operating conditions.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 0.75 MW/Day |
| Land & Building (12000 sq.mt.) | Rs. 14.47 Cr |
| Plant & Machinery | Rs. 3.45 Cr |
| Working Capital for 1 Month | Rs. 35.07 Cr |
| Total Capital Investment | Rs. 80.70 Cr |
| Rate of Return | 57% |
| Break Even Point | 31% |
Content Index
- INTRODUCTION
- CELLS MODULES AND ARRAYS
- PHOTOVOLTAIC CELL
- PHOTOVOLTAIC MODULES
- SINGLE CRYSTALLINE
- STRING RIBBON
- PHOTOVOLTAIC PANELS
- PHOTOVOLTAIC ARRAY
- PROJECT LOCATION-AHMEDABAD (GUJRAT)
- WEATHER
- CITY MAP OF AHMEDABAD
- TRANSPORTATION
- BY AIR:-
- BY ROAD:
- BY TRAIN:
- 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
- LONGEVITY
- 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
- 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: 2
- LAY-UP: 2
- INTERCONNECTION 1
- LAMINATORS: 2
- SOLAR PV MODULE 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:
- 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
- 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
- FUNCTION:
- CHARACTERISTICS:
- ADVANTAGES:
- 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
- J BOX WORKING TABLES
- J BOX POTTING DISPENSING MACHINE
- J BOX 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
A solar PV module is an assembled unit of photovoltaic cells designed to convert sunlight into electrical energy. Individual cells are electrically connected and encapsulated between protective materials such as EVA, glass, and a backsheet. The assembly is generally completed with an aluminium frame and junction box with bypass diodes. Solar PV modules can be used in rooftop systems, power plants, telecommunications, pumping, lighting, refrigeration, and other applications requiring electrical power.
Solar panel manufacturing generally involves cell inspection, cell interconnection, stringing, lay-up, bussing, encapsulation, lamination, trimming, framing, junction box installation, curing, electrical testing, inspection, and module sorting. The report also identifies automated equipment for several of these operations. Lamination is a particularly important stage because it encapsulates and protects the interconnected photovoltaic cells. Final electrical and visual inspections help verify the quality and performance of the finished module.
Common solar PV module materials include photovoltaic solar cells, EVA encapsulant, tempered glass, a backsheet, aluminium framing, connecting ribbons, a junction box, bypass diodes, connecting cables, and silicone sealant. Each material performs a specific function in the module. Glass provides front-side protection, EVA encapsulates the cells, the backsheet protects the rear surface, and the aluminium frame provides structural support. The junction box and electrical connections provide the interface for safely transferring generated electricity.
Lamination is important because it permanently encapsulates the interconnected solar cells within protective layers. During this stage, the cell assembly is bonded with the encapsulant and protected by the front glass and rear surface material. Proper lamination helps provide mechanical protection and supports the long-term integrity of the module. Manufacturing parameters must be controlled carefully because inadequate processing can affect module quality, reliability, and performance during subsequent operation.
Solar PV modules are tested using electrical and performance measurements, including flash testing. Flash testing evaluates parameters such as open-circuit voltage (VOC), short-circuit current, current at maximum power point, voltage at maximum power point (VMP), fill factor (FF), and maximum power. Measurements are made under defined standard testing conditions so that module performance can be evaluated consistently. Additional electrical inspections and testing help identify manufacturing defects and verify that modules meet the required performance and quality criteria.
Quality control in solar manufacturing requires monitoring both raw materials and production parameters throughout the process. Silicon and wafers can be evaluated for purity, resistivity, crystal orientation, oxygen and carbon content, bending, damage, polishing, sawing, and etching defects. Production conditions such as temperature, pressure, speed, and dopant quantities also require control. Electrical testing verifies current, voltage, and resistance characteristics, while module-level inspections and field testing help confirm performance under operating conditions.
Photovoltaic technology is used across residential, industrial, telecommunications, public-service, healthcare, and utility applications. Solar power systems can support rooftop electricity generation, water pumping, lighting, refrigeration, telecommunications equipment, and larger power-generation installations. Photovoltaic modules can also be integrated into different electrical system configurations depending on the application. Their ability to convert solar radiation directly into electricity makes them suitable for both distributed and larger-scale electricity generation.
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