Industry Overview
Solar PV modules are assemblies of photovoltaic cells that convert sunlight directly into direct current (DC) electricity. Individual modules can be connected in series and/or parallel to form panels and complete photovoltaic arrays capable of delivering the voltage and current required by a particular system.
The photovoltaic effect, discovered by Edmund Becquerel in 1839, is the fundamental principle behind solar electricity generation. PV technology advanced significantly in the early 1950s as photovoltaic cells emerged from developments in transistor technology. Initially used as a costly power source for satellites, improvements in manufacturing and materials have progressively reduced costs, supporting wider use in homes, businesses, industry, telecommunications and public services.
Modern PV modules primarily use semiconductor materials such as highly purified silicon. Commercial module technologies described in the report include single crystalline, polycrystalline or multicrystalline, string ribbon, and amorphous or thin-film technologies. Modules generally comprise interconnected cells protected by materials such as tempered glass, EVA encapsulant, backsheets, aluminium frames and junction boxes.
PV modules and arrays are typically rated under Standard Test Conditions (STC), although field performance can vary with operating conditions. The report also covers PV module construction, electrical characteristics, system requirements, manufacturing processes, production-line equipment, raw materials, suppliers, market conditions, and the proposed project location in Kadapa District.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 200 MW/Day |
| Land & Building (800 sq.mt.) | Rs. 81.07 Cr |
| Plant & Machinery | Rs. 336 Cr |
| Working Capital for 1 Month | Rs. 53 Lac |
| Total Capital Investment | Rs. 500.26 Cr |
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- KADAPA DISTRICT
- MAP
- CLIMATE
- TRANSPORT
- KADAPA AIRPORT TERMINAL
- ROADWAYS
- RAILWAYS
- AIRWAYS
- 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
- 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
- EQUATION BELOW;
- LOW LIGHT INTENSITY
- LINE CAPACITY
- SOLAR PV MODULE SPECIFICATION
- (A) MECHANICAL SPECIFICATION
- (B) ELECTRICAL SPECIFICATION
- SOLAR SYSTEM TYPICAL AND MINIMUM SITE REQUIREMENTS
- MINIMUM SUNLIGHT REQUIREMENTS FOR SOLAR SYSTEMS
- THE BOTTOM LINE IS, EVEN SCATTERED SUNLIGHT CAN PROVIDE SOLAR POWER. THE KEY QUESTION THEN, BECOME:
- HOW MUCH SURFACE AREA WILL BE REQUIRED IN ORDER TO GENERATE THE DESIRED AMOUNT OF POWER?
- WILL THAT BE AVAILABLE WITHIN THE PROPOSED SOLAR SYSTEM SITE?
- WILL A SYSTEM OF THE REQUIRED SURFACE BE BE FINANCIALLY VIABLE, TO COVER THE COSTS INITIALLY AND TO RECOUP THAT INVESTMENT OVER TIME?
- PLANNING PERMISSIONS AND INSPECTIONS
- THERE ARE TWO FUNDAMENTAL ISSUES TO BE ADDRESSED HERE AT HIGH LEVEL:
- THE FOLLOWING LIST IS REPRESENTATIVE OF THE AREAS WHERE REQUIREMENTS WILL NEED TO BE SATISFIED:
- STRUCTURAL AND MECHANICAL STABILITY
- FIRE SAFETY
- ENVIRONMENT REQUIREMENTS (HYGIENE, HEALTH & THE ENVIRONMENT)
- SAFETY IN USE
- NOISE LEVELS AND PROTECTION AGAINST NOISE (IF ONLY DURING INSTALLATION)
- ENERGY ECONOMY AND HEAT RETENTION
- SUSTAINABLE USE OF NATURAL RESOURCES
- SOLAR SYSTEM REQUIRED COMPONENTS
- AT THE SIMPLEST LEVEL, A SOLAR SYSTEM REQUIRES:
- CONNECTING TO YOUR LOCAL POWER GRID
- SOLAR SYSTEM TYPICAL REQUIREMENTS
- THEREFORE, FOR THE PURPOSES OF GENERAL GUIDANCE, A TYPICAL DOMESTIC ROOFTOP SYSTEM CONSISTS OF:
- 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
- LIGHTING OF STREETS, GARDENS AND PUBLIC TRANSPORTATION STOPS STREET SIGNALLING.
- 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 & 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
- GROWING NUMBER OF UTILITY SCALE SOLAR PROJECTS WILL AUGMENT THE MARKET GROWTH
- PV PRODUCTION LINE
- M-01 AUTOMATIC GLASS LOADING
- M-02 AUTOMATIC ENCAPSULANT CUTTING AND LOADING
- FUNCTION:
- DESCRIPTION:
- M-03 AUTOMATIC TEMPLATE LOADING
- M-04 INSPECTION TABLE
- M-05 TABBER AND STRINGER MTS-3000
- HIGHLIGHTS:
- MAIN FEATURES:
- LIST OF EQUIPMENT INCLUDED:
- M-06 LAY-UP SYSTEM
- M-07 MIRROR INSPECTION TABLE
- M-08 AUTOMATIC BUSSING IC100 (3 HEADS
- M-9 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
- M15 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
- APPENDIX – A:
- 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 assembly of photovoltaic cells designed to convert sunlight directly into DC electricity. The cells are electrically interconnected and protected within an environmentally resistant structure that commonly includes glass, encapsulant, a backsheet, frame and junction box. Multiple modules can be connected in series or parallel to achieve the required electrical output. PV modules are fundamental building blocks of solar photovoltaic systems used in residential, commercial, industrial and utility-scale applications.
A photovoltaic cell generates electricity through the photovoltaic effect, in which absorbed sunlight produces an electrical potential and current. A typical silicon cell contains semiconductor layers with different electrical properties, creating a voltage difference. When photons from sunlight interact with the material, electrons are energized and can move through an external electrical circuit. Metallic contacts collect the electrical charge, allowing current to flow. The cell itself does not store electricity; it generates electrical energy while suitable light is available.
The main components of a solar PV module include PV cells, glass, EVA film, a backsheet, aluminium frame, junction box, bypass diodes and electrical connections. The PV cells perform the energy conversion, while the glass and encapsulant provide environmental protection. The backsheet provides rear-side protection, and the frame gives mechanical support. The junction box provides electrical connections and commonly incorporates bypass diodes to support module operation under conditions where portions of the module are shaded.
Monocrystalline and polycrystalline modules differ mainly in their silicon structure and manufacturing approach. Monocrystalline modules use cells manufactured from single-crystal silicon and are generally associated with higher conversion efficiency. Polycrystalline or multicrystalline modules are produced from silicon with multiple crystal structures and have historically offered lower manufacturing costs with somewhat lower efficiency. The choice between technologies depends on factors such as available area, required output, product specifications, system design and overall project economics.
The solar PV module manufacturing process involves preparing and interconnecting cells, laying up the module layers, laminating the assembly, trimming and framing, installing the junction box, curing, testing and sorting. Production lines can include glass loading, encapsulant cutting and loading, cell tabbing and stringing, lay-up, bussing, electroluminescence inspection, lamination, edge trimming, optical inspection, framing, junction-box operations and final module testing. Automation levels vary according to production requirements and equipment configuration.
Solar PV module manufacturing requires photovoltaic cells and several protective and structural materials. The report identifies solar cells, EVA encapsulant, tempered glass, aluminium frames, junction boxes, silicon gel, thermoplastic back sheets and connecting ribbons among the relevant materials and components. Manufacturing requirements can vary according to module technology and product design. Consistent material quality is important because the module must provide electrical performance while withstanding environmental exposure and maintaining mechanical and electrical integrity throughout its service life.
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