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Soleos

6 Ways Solar Module Installation Saves You Money Long-Term

Posted on by Soleos
Solar Module Installation
30
Jul

In the face of climate change and rising energy costs, solar module installation has emerged as a powerful, long-term solution. It is not just about reducing electricity bills—it’s about empowering homes and industries to be energy independent, eco-conscious, and future-ready. Whether you’re a homeowner looking to reduce your carbon footprint or a manufacturing plant seeking to cut down operational expenses, installing solar modules is a game-changing decision.

What is Solar Module Installation?

Solar module installation is the process of installing solar panels on surfaces like rooftops, ground structures, or carports to convert sunlight into electricity. It involves the physical and electrical integration of the solar energy system, transforming passive sunlight into active energy savings. This process involves mounting photovoltaic (PV) panels on structures and integrating them into a functional solar power system to generate clean electricity.

Solar module installation is essential for enabling solar panels to transform sunshine into usable electricity. This system reduces energy bills, supports sustainability goals, and empowers businesses and homes to generate renewable energy independently.

Types of Solar Module Installations

1. Monocrystalline PV Modules

  • Made from single-crystal silicon wafers—uniformly black in appearance.
  • Highest commercial efficiency (≈ 15–22%) → ideal when space is limited.
  • More costly but offers better long-term performance.

2. Polycrystalline PV Modules

  • Constructed from multiple silicon crystals; typically blue-speckled.
  • Efficiency around ~15%, lower cost than monocrystalline.
  • Requires more area for comparable energy output.

3. Thin-Film Modules

  • Flexible and lightweight; uses materials like CdTe, CIGS, or amorphous silicon.
  • Efficiency ranges roughly 10–12%; often used in large-scale utility setups.
  • Cost-effective for large areas and adaptable design.

4. Bifacial Modules

  • Can generate power from both front and rear surfaces.
  • When combined with tracking systems, can boost annual output by 10–30%.

5. Hybrid Photovoltaic-Thermal (PVT) Modules

  • Produce electricity while capturing heat from the same panel.
  • Enhanced overall efficiency; heat may be used for domestic water or HVAC.

6. Building-Integrated Photovoltaics (BIPV)

  • Modules integrated into building materials.
  • Examples include solar shingles and semi-transparent wall panels.
  • Offers aesthetics and dual functionality (structure + energy).

Step-by-Step Process of Solar Module Installation

Site Assessment and Feasibility Study

Professionals conduct site surveys to assess roof or ground conditions, including roof orientation, structural strength, shading issues, and available space. They also evaluate energy usage and solar system types. Engineers evaluate the location to understand space, sunlight availability, shading, roof angle, and structure. The process starts with an estimate of energy required and property measurement. The roof should be sound, have a lifespan of 15-20 years, and catch direct sunlight. The orientation and tilt of the roof, and shading analysis, should also be considered.

System Design and Engineering

Engineers create a custom solar layout based on energy needs, roof area, panel orientation, and preferred inverter type. Permits and incentive applications are arranged. After site analysis, a solar system is designed based on daily electricity usage, system size, and type of inverter. The layout is tailored to your energy needs, available space, and budget, ensuring an efficient and cost-effective solution.

Procuring Equipment

The solar system comprises monocrystalline, polycrystalline, bifacial, or smart modules, an inverter for DC to AC power conversion, mounting structures, UV/temperature-resistant cabling, and MC4 connectors, all sourced from reputable sources.

Mounting Structure Installation

Solar panels are installed on a solar array using a secure mounting system. The frame is anchored to withstand wind, rain, and temperature changes, and the panels are bolted with precise spacing for optimal sun exposure. The tilt angle is set at the location’s latitude for maximum annual yield. The mounting structure is prepared for stability and durability, with roof-mounted systems using brackets and ground-mounted options using sturdy frames. The structure is then installed according to manufacturer’s specifications, with proper alignment for optimal energy capture. The system provides a solid foundation for the solar cells, ensuring their longevity and performance.

Electrical Wiring and Connection

Solar panels are wired in series or parallel based on voltage and current requirements, using MC4 connectors and weather-resistant conduit. Wiring must follow local electrical standards and include earthing and surge protection. All DC lines feed into the inverter, which connects to the AC electrical panel or energy storage system. Correct wiring is crucial for the system’s functionality, with series connections increasing voltage and parallel setups enhancing amperage. Insulation is essential to avoid short circuits and hazards, and using electrical conduit shields wiring promotes safety and extends installation lifespan. Well-organized wiring facilitates aesthetics and future maintenance.

Testing and Commissioning

Initial testing verifies connections, insulation resistance, and grounding, while performance testing measures voltage, current, and efficiency of panels and inverters. Comprehensive documentation is compiled, and final inspections by local authorities and utilities enable grid interconnection or net-metering permissions. Testing is crucial for commissioning, including PV modules, earthing, inverters, and wiring. Insulation resistance is one of the first tests, ensuring no leakage current. As the plant is expected to last 25 years, recording resistance values and tracking them over the plant’s life can provide valuable information on insulation deterioration and quality.

Cost of Solar Module Installation

Residential Solar Installation Costs

System Size & Price Range (Before Subsidy)

  • 1 kW: ₹45,000 – ₹75,000
  • 3 kW: ₹1.9 – 2.4 lakh
  • 5 kW: ₹3.15 – 3.57 lakh
  • 7–10 kW: ₹4.0 – 4.6 lakh

Subsidy Scheme: PM Surya Ghar Muft Bijli Yojana

  • ₹30,000 per kW for first 2 kW
  • ₹18,000 for 3rd kW
  • Total max subsidy = ₹78,000

Subsidy Scheme: PM Surya Ghar Muft Bijli Yojana

  • 1 kW: ₹15,000 – ₹45,000
  • 3 kW: ₹1.12 – 1.62 lakh
  • 5 kW: ₹2.37 – 2.79 lakh

Commercial & Industrial Installations

  • Typical cost ranges from ₹35,000 – ₹50,000 per kW, depending on scale, complexity, and panel type
  • Installation costs include mounting, wiring, inverter, PDU, labor, and approvals per kW at ₹10–15/W

Decision-makers often see shorter ROI with larger systems due to economy of scale, tax benefits (accelerated depreciation, GST credits), and minimal maintenance requirements

Benefits of Solar Module Installation

1. Substantial Cost Savings & ROI

  • Slash your electricity bills — Systems can offset 70–90% of your energy usage, depending on size and usage patterns.
  • Fast payback — Many residential and commercial setups pay for themselves within 3–5 years, with decades of free energy ahead.
  • Net metering allows you to sell surplus energy back to the grid, turning unused capacity into utility credits or revenue.

2. Environmental Impact & Sustainability

  • Clean & renewable energy — Solar power emits zero greenhouse gases during generation, reducing carbon footprints and air pollution.
  • Supports India’s green goals — Huge deployments across Gujarat and other states are already avoiding thousands of tons of CO₂ emissions.
  • Reduced fossil fuel dependency strengthens national energy security and resilience.

3. Energy Independence & Grid Security

  • Self-generation empowers manufacturers — Decisions-makers control energy flows, reducing vulnerability to grid instability and escalating tariffs.
  • Battery backup or hybrid systems can maintain operations during blackouts, ensuring uninterrupted power for critical C&I workloads.

4. Low Maintenance & High Reliability

  • Minimal upkeep — With no moving parts, systems typically need only periodic cleaning and annual checks to sustain peak performance.
  • Durability guaranteed — Most solar modules come with 25-year performance warranties and often operate efficiently well beyond 30 years.

5. Boosted Asset Value & Brand Image

  • Property resale value increases — Solar-equipped properties command a premium (around 3–4% more) in valuations.
  • Strengthen corporate reputation — Installing solar improves Corporate Social Responsibility (CSR), resonates with eco-conscious customers, investors, and employees.

6. Government Incentives & Economic Benefits

  • Subsidies make systems accessible — Example: indicates up to ₹78,000 subsidy for residential systems under PM Surya Ghar Yojana.
  • Tax advantages for C&I — Accelerated depreciation (40%), GST input credits, and state-specific rebates maximize returns.
  • Broad promotion of rooftop solar — Large-scale government programs (e.g. PM Surya Ghar) are streamlining approval and subsidy flows at scale.

7. Economic Growth & Job Creation

  • Local employment — Every solar installation fuels jobs across EPC, logistics, maintenance, and manufacturing, driving local economic uplift.
  • Stimulates green sector innovation — Expanding solar systems supports the ecosystem of advanced technology and skilled labor.

8. Operational Advantages & Scalability

  • Flexible system design — From rooftops to carports, and agrivoltaics, solar can adapt to varied industrial architectures.
  • Scalable over time — Manufacturers can pilot a smaller system and gradually expand capacity as the business grows

Challenges in Solar Module Installation and Their Solutions

1. Structural & Safety Risks

  • Problem: Substandard mounting structures may collapse during storms—panels have flown off rooftops in 120 km/h winds in places like Indore and Bhopal. These systems fail within a few years due to rust and poor design.
  • Solution: Use engineered, pre‑fabricated mounting systems (like those certified to IIT standards) capable of withstanding wind speeds up to 170 km/h, along with professional structural engineering assessments.

2. Quality & Durability Concerns

  • Problem: Many panels degrade prematurely—warranty periods end after just 8–12 years due to micro-cracks, poor soldering, and unsuited build materials for India’s climate.
  • Solution: Prioritize Tier-1 modules with long-term performance warranties and quality certifications. Implement routine monitoring and quality audits post-installation.

3. Dust, Soiling & Water Scarcity

  • Problem: Dust accumulation in regions like Rajasthan and Gujarat lowers module efficiency by up to 30%. Combined with water hardness, cleaning becomes costly and difficult.
  • Solution: Schedule regular cleaning (especially in dusty zones), use water treated via RO systems, consider automated or hydrophobic coatings, and employ dry-cleaning technologies where viable.

4. Shading & Site-Specific Design Issues

  • Problem: Shadows from trees, HVAC, or surrounding obstructions can significantly reduce yield and cause hot spots.
  • Solution: Conduct detailed shading analysis during planning. Deploy micro-inverters or optimizers to mitigate output loss and adjust layouts to avoid shading zones.

5. Grid Integration & Electrical Constraints

  • Problem: Reverse power flow, intermittent PV output, and voltage variability can destabilize distribution systems that weren’t designed for bi-directional power flow.
  • Solution: Implement smart grid tech, energy storage solutions (like lithium-ion batteries), and O&M remote monitoring to smooth generation ramps and balance feed-in across the grid.

6. Regulatory, Permitting & Policy Barriers

  • Problem: Complex approvals, inconsistent state-by-state net-metering rules, and coordination delays with DISCOMs slow rollout and frustrate consumers.
  • Solution: Work with EPC partners that provide single-window assistance, standardize net-metering application with utilities, and ensure accurate digital submission for subsidy eligibility.

7. Financial & Market Challenges

  • Problem: High up-front costs, uncertain subsidy disbursals, import duties on components, and fluctuating availability impact feasibility.
  • Solution: Leverage government loans, solar financing programs, green bonds, and local manufacturing schemes under “Make in India” to reduce reliance on imports and secure financing stability.

8. Skilled Workforce Shortage

  • Problem: Limited availability of qualified designers and certified installation teams leads to errors, delays, and compromised quality.
  • Solution: Invest in vocational training, certifications, and partnerships with technical institutes. EPC companies should standardize and standard-operating-procedure their workforce operations.

9. Health & Occupational Safety Concerns

  • Problem: Workers face risk of falls, electrocution, ergonomic strain, and exposure to toxic materials during installation or handling waste panels.
  • Solution: Enforce strict safety protocols: harness use, electrical isolation, PPE, worker training, and safe e-waste disposal practices.

10. End-of-Life and Waste Management

  • Problem: With solar panel installations expected to reach 50–325k tonnes of waste by 2030, informal recycling and improper disposal pose environmental risks.
  • Solution: Implement recycling programs under E-waste regulations, support producer responsibility legislation, and develop infrastructure for safe PV module disposal.

Government Incentives for Solar Module Installation

PM Surya Ghar: Muft Bijli Yojana (Flagship Residential Rooftop Solar Scheme)

  • Launch & Mandate
    Approved on February 29, 2024, this ₹75,021 crore MNRE-backed initiative targets 1 crore residential rooftops by March 2027, offering free electricity up to 300 units/month.
  • **Subsidy Structure (Central Financial Assistance / CFA)**
    ‣ Up to 2 kW: 60% subsidy (~₹30,000/kW)
    ‣ 2 – 3 kW: 40% of additional cost (cap at ₹78,000 for > 3 kW)
    ‣ Max subsidy: ₹78,000 for systems ≥ 3 kW.
  • Eligibility & Application
    Open to Indian citizens with valid electricity connections and suitable rooftops. Must not have received previous solar subsidies. Apply through the MNRE portal —includes feasibility approvals, vendor selection, net-metering, and inspection workflows. Subsidy is credited to the bank account within ~30 days post-installation.
  • Additional Benefits
    ‣ Collateral-free loans up to ₹2 lakh at ~7% interest available.
    ‣ One Model Solar Village created per district to showcase implementation.
    ‣ Scheme expected to generate ~17 lakh direct jobs and add ~30 GW of rooftop solar capacity.

Best Practices for Successful Solar Module Installation

1. Thorough Site Assessment and Feasibility Study: Before installation, analyze roof space, orientation, shading, structural analysis, and solar irradiance mapping to ensure long-term physical and financial viability of the system.

2. Optimal System Design: Utilize high-efficiency solar modules suitable for your climate zone, select an inverter that matches capacity and voltage needs, and design for minimal transmission losses and maximum energy yield.

3. Quality Equipment and Materials: Select Tier 1 solar modules, premium mounting structures, and reliable balance-of-system components for improved performance and a 25+ year system life.

4. Skilled EPC Partner: Partner with a professional Solar EPC company like Soleos Solar for proven C&I experience, on-time delivery, and certified engineers to avoid costly rework, compliance issues, and operational downtime.

5. Adherence to Safety and Compliance Standards:The guidelines include BIS and MNRE guidelines, international standards like IEC and ISO, local DISCOM and fire safety codes, emphasizing safety first by integrating grounding, surge protection, and fire-resistant cabling.

6. Efficient Installation Planning: Schedule for low-rain seasons, coordinate civil, electrical, and logistics teams, and use appropriate tools for alignment, torque, and angle calibration.

7. Monitoring System Integration: Smart solar monitoring systems, whether cloud-based or on-premises, can track generation, identify faults quickly, and enable predictive maintenance, with mobile app access and remote diagnostics recommended.

8. Post-Installation Testing and Commissioning: Perform IV curve, insulation resistance, and thermal imaging tests, verify inverter synchronization and grid connectivity, and ensure full load testing before handover.

9. Operations & Maintenance (O&M) Plan: Implement a preventive maintenance schedule, including panel cleaning, electrical checks, and visual inspections, and outsource O&M to a reliable provider for warranty compliance and uninterrupted performance.

10. Documentation and Warranty Management: The document includes equipment datasheets, warranty certificates, single-line diagrams, layout drawings, and maintenance logs, ensuring transparency and supporting future audits, resale, or scale-up.

The future of solar module installation is experiencing a revolutionary transformation fueled by advancements in technology, automation, and a global shift toward sustainability. Innovations such as bifacial solar modules—which generate power from both sides—are significantly enhancing energy yields, making solar module installation more efficient and productive than ever. At the same time, cutting-edge perovskite-silicon tandem cells are pushing efficiency levels beyond 30%, redefining the standards for high-performance solar module installation across residential, commercial, and industrial sectors.

Aesthetic integration is also becoming a key focus, with Building-Integrated Photovoltaics (BIPV) making solar module installation more seamless and visually appealing in modern architecture. Additionally, smart technologies like AI-powered monitoring and predictive maintenance are now essential components of intelligent solar module installation, ensuring reliability, early fault detection, and minimal downtime. Automation is also playing a major role in the future of solar module installation, with robotic systems and drones drastically reducing labor time, increasing safety, and enabling faster project completion on large-scale solar farms.

Emerging practices such as agrivoltaics are redefining land use by combining agriculture with solar module installation, while floating solar systems are utilizing water surfaces to boost efficiency and conserve space. The integration of advanced battery storage solutions with solar module installation is enabling around-the-clock power supply, offering greater energy security and autonomy for manufacturing and industrial units. Moreover, enhanced safety protocols—like arc fault detection and rapid shutdown systems—are now a core part of commercial solar module installation strategies, ensuring compliance and protection.

Finally, with trends like peer-to-peer energy trading and decentralized power generation gaining traction, solar module installation is becoming more accessible, scalable, and financially rewarding. Altogether, these innovations mark a new era in solar module installation, empowering businesses and communities to embrace a smarter, more resilient, and sustainable energy future.

Why Choose Soleos Solar for Your Solar Module Installation?

When it comes to solar module installation, Soleos Solar stands out as a trusted industry leader with over 12 years of global expertise and a portfolio exceeding 450MW+ of successful projects. We specialize in end-to-end EPC solutions for commercial, industrial, and utility-scale solar systems—tailored to maximize performance, efficiency, and long-term ROI. At Soleos Solar, we don’t just install panels—we engineer energy independence. From advanced site assessment and precision design to world-class components and smart monitoring systems, our approach to solar module installation ensures quality, compliance, and sustainability at every step.

Whether you require a rooftop, ground-mounted, agrivoltaic, or solar carport system, our team delivers customized solutions with minimal disruption and maximum reliability. With a strong presence in India, the UK, UAE, Germany, Kenya, Spain, and Portugal, Soleos Solar brings international standards to every local installation. Choose Soleos Solar for your solar module installation—where innovation meets execution, and your transition to clean energy becomes smooth, secure, and scalable.

Conclusion

As global energy dynamics shift, solar module installation is redefining how industries approach sustainability and savings. With innovations like bifacial panels, real-time performance monitoring, and AI-powered energy optimization, solar technology is not only reliable—it’s revolutionary. Businesses that invest in solar today gain more than energy efficiency; they earn a competitive edge and environmental leadership. At Soleos Solar, we combine global expertise with localized support to deliver future-ready solar module installation for commercial and industrial leaders. Our solutions are designed to reduce your carbon footprint, cut electricity costs, and ensure seamless scalability.

Ready to embrace solar for your business? Contact Soleos Solar today to schedule a consultation and power your future with clean, intelligent energy.

Frequently Asked Questions (FAQs)

1. What is solar module installation?

Solar module installation refers to the process of setting up photovoltaic (PV) panels to capture sunlight and convert it into electricity. This includes site assessment, system design, mounting structure installation, electrical connections, and system testing.

2. How long does it take to install solar modules?

The time required varies depending on the project size. For most commercial and industrial setups, solar module installation can take anywhere from 1 week to 4 weeks, including site preparation and commissioning.

3. What is the average lifespan of solar modules?

Most high-quality solar modules come with a performance warranty of 25 years, but they can last up to 30 years or more with proper maintenance.

4. How much space is needed for solar module installation?

Space requirements depend on your energy goals. For industrial rooftops or ground-mount systems, expect to need 100–120 sq. ft. per kW of solar installation.

5. What are the key benefits of installing solar modules?

  • Lower electricity bills
  • Government subsidies & tax benefits
  • Low maintenance
  • Sustainable and eco-friendly power
  • Increased property value
Soleos, News & Press

8 Trends Shaping the Future of Solar Module Manufacturing

Posted on by Soleos
Solar Module Manufacturing
19
Jul

At Soleos Energy Private Limited, we believe the future is solar. As global energy needs rise and the call for sustainability grows louder, solar module manufacturing stands at the heart of the green revolution. Solar modules—often referred to as solar panels—are the core component that converts sunlight into usable electricity.

In this in-depth blog, we walk you through the complete journey of solar module manufacturing—from raw materials to a high-performing solar panel installed on rooftops, ground mounts, or solar parks. We’ll explore technologies, materials, processes, trends, and market leaders to offer a full-circle understanding of this dynamic sector.

What is Solar Module Manufacturing?

Solar module manufacturing is the process of creating photovoltaic (PV) modules, which convert sunlight into electricity. It involves the step-by-step fabrication of solar panels from raw materials like silicon into fully assembled, tested, and ready-to-install modules, ensuring durability and weather resistance.

Core Stages of Solar Module Manufacturing

1. Polysilicon Production

Polysilicon is a high-purity, fine-grained crystalline silicon product, typically in the shape of rods or beads. It is produced using highly reactive gases, primarily metallurgical-grade silicon, hydrogen, and chlorine. The Siemens process involves passing a silicon-hydrogen-chlorine compound gas over a heated silicon filament, breaking molecular bonds and depositing silicon atoms. The hydrogen and chlorine atoms are reused in a closed cycle. Another method involves placing small silicon beads at the bottom of an inverted cone-shaped vessel, where a compound gas of silicon and hydrogen is pumped in, breaking bonds and depositing silicon atoms. 

2. Ingot and Wafer Production

Polysilicon is transformed into wafers through various processes, including the Czochralski process and directional solidification. The liquid mass is heated to form a liquid mass, which is then sliced into thin wafers using diamond-coated wire saws. The resulting silicon sawdust, called kerf, is then used to create a wafer. Kerfless wafer production can also be achieved by pulling cooled layers off a molten bath or depositing a thin layer of silicon atoms onto a wafer template. 

3. Cell Fabrication

Silicon wafers are fabricated into photovoltaic cells through chemical texturing to remove saw damage and increase light exposure. The process varies depending on the device architecture, with most cell types requiring exposure to an electrically active dopant gas and coating surfaces with layers for improved performance. Screen printing of silver metallization is also common.

4. Module Assembly

Module assembly involves connecting silver busbars in cells using copper ribbons plated with solder. The interconnected cells are arranged face-down on a glass sheet covered with polymer encapsulant, followed by a polymer backsheet or glass. The stack is laminated in an oven for waterproofing, fitted with an aluminum frame, edge sealant, and a junction box. The ribbons are connected to diodes to prevent backward electricity flow. Electrical cables from the junction box convey module current to adjacent modules or power electronics.

The Importance of Solar Module Manufacturing in the Renewable Ecosystem

1. Powering the Clean Energy Transition

Solar modules are the heart of solar power systems. Without them, there is no solar energy. By enabling the mass production of affordable, efficient modules, manufacturers accelerate the shift from fossil fuels to renewables—helping countries meet their clean energy targets faster.

2. Strengthening Energy Independence

Manufacturing solar modules domestically reduces reliance on imports, shields nations from global price shocks, and strengthens energy security. In countries like India, this supports the Atmanirbhar Bharat (Self-Reliant India) mission by building resilient, local suply chains.

3. Driving Industrial Growth and Employment

Every gigawatt (GW) of solar module manufacturing capacity generates 1,000–1,300 direct jobs. It also supports indirect employment across logistics, R&D, testing labs, maintenance, and installation. Solar manufacturing is becoming a backbone industry for sustainable industrial development.

4. Enabling Innovation and Technological Advancement

Manufacturing is the launchpad for innovations like:

  • PERC, TOPCon, and HJT solar cells
  • Bifacial and thin-film solar modules
  • Smart modules with integrated monitoring systems

Such breakthroughs improve energy yield, reduce costs, and expand the applications of solar—from rooftops to floating solar, to agrivoltaics.

5. Supporting Climate and ESG Goals

Sustainable solar module manufacturing contributes to global climate commitments by reducing the carbon footprint of solar energy production. Manufacturers are adopting:

  • Green energy-powered factories
  • Lead-free soldering
  • Module recycling initiatives
  • Water conservation techniques

6. Accelerating Utility-Scale and C&I Deployments

With growing demand in commercial & industrial sectors and utility-scale solar farms, manufacturing must keep pace to supply high-quality panels quickly and cost-effectively. Fast, flexible, and local module production helps projects avoid delays and maintain profitability.

7. Ensuring Quality and Climate Adaptability

Local manufacturing allows customization of modules to specific climate conditions—whether it’s coastal humidity, high temperatures, or desert winds. This increases durability, performance, and the lifespan of solar power systems, especially in challenging industrial environments.

8. Influencing Energy Markets and Policy

As countries ramp up solar deployment, solar module manufacturing becomes a strategic sector. Policies like:

  • PLI (Production Linked Incentive) in India
  • ALMM (Approved List of Models and Manufacturers)
  • Solar import duties

are reshaping trade, investment, and job creation. Manufacturing is no longer a backend process—it’s now central to clean energy policy and global competitiveness.

Key Raw Materials in Solar Module Manufacturing

To understand the intricacies of solar module manufacturing, it’s essential to know the key materials involved:

1. Silicon

Solar cells use semiconductors, which are sliced into thin wafers after purification. They make up over 90% of the global PV market. Monocrystalline is more efficient but expensive, while polycrystalline is cost-effective but slightly less efficient.

2. Glass

Tempered solar glass, typically 3.2mm in size, is a protective front layer for solar modules, offering high transparency and anti-reflective coatings to enhance light capture and protect internal components from weather, dust, and mechanical damage.

3. Encapsulants (EVA or POE)

This protective adhesive layer between glass, solar cells, and backsheet cushions cells, prevents moisture ingress, maintains optical transparency, and provides electrical insulation. High-quality EVA ensures module longevity and performance, with transparent polymer for stability.

4. Backsheet

Multi-layered polymer sheets made from PVF, PET, or PVDF provide electrical insulation and protection against moisture and UV, ensuring module long-term durability and protection from environmental damage.

5. Aluminum Frame

The module’s mechanical strength and support are provided by lightweight, corrosion-resistant materials, which are compatible with standard mounting systems. Copper and aluminum are used in busbars and framing, aiming to reduce costs without compromising efficiency.

Step-by-Step Process of Solar Module Manufacturing

1. Silicon Purification & Ingot Growth

  • Quartzite is heated in electric furnaces to form metallurgical-grade silicon, which is refined using the Siemens process into pure polysilicon. This is then cast into monocrystalline or polycrystalline ingots, often in vacuum systems to eliminate impurities. The process is crucial as impurities reduce efficiency and cause cell degradation. The goal is to form solid blocks of pure silicon crystals, with monocrystalline grown using the Czochralski process and polycrystalline formed by casting molten silicon into square molds.

2. Wafer Slicing

  • The process involves cutting ingots into ultra-thin wafers using diamond-coated wires, resulting in clean, smooth wafers ready for solar cell processing. Thinner wafers reduce material use and costs, while acid-etching removes saw damage and enhances light absorption.

3. Solar Cell Fabrication

  • Electricity generation involves doping wafers with phosphorus or boron to create p-n junctions, which are essential for current flow. Texturing and anti-reflective coatings like silicon nitride enhance light capture. Metalization involves silver paste for front contacts and aluminum or copper for rear. Screen printing is done with silver paste for front contacts and aluminum for back, followed by high-temperature treatment for solidifying metal contacts.

4. Cell Testing and Sorting

  • The objective is to test electrical characteristics such as open-circuit voltage, short-circuit current, and efficiency in a module. Cells are sorted by performance to ensure uniformity, as mixing different grade cells can lower efficiency.

5. Cell Interconnection (Tabbing/Stringing)

  • Solar panels consist of solar cells interconnected in strings using copper ribbons through manual or automated soldering. The layout typically includes 60-cell, 72-cell, or 144 half-cut-cell configurations, with good interconnection minimizing electrical loss.

Technologies in Solar Module Manufacturing

Modern solar module manufacturing leverages advanced technologies to improve yield and performance:

1. PERC, TOPCon & HJT Cell Architectures

The Passivated Emitter Rear Cell (PERC) enhances light capture and efficiency by 22-23%, while TOPCon and HJT cells increase efficiency by 28-30%, enhancing energy yield in C&I projects. These technologies, widely adopted globally, improve cell performance without significantly increasing costs, making them the most widely adopted tech globally.

2. Bifacial Modules

Biacial panels capture sunlight from both front and rear sides, boosting energy yield by up to 30%. Ideal for ground-mounted, floating solar, and carport installations, they capture both direct and reflected sunlight, enhancing yield by up to 30% in high-albedo settings. Floatovoltaics use cooling water bodies to increase efficiency and conserve land.

3. Automation, AI & Digital Twin Manufacturing

Modern factories employ AI/vision robots, cleanroom environments, and materials-handling systems to minimize micro-cracks and defects. Digital twins simulate production lines, enabling predictive quality assurance and reducing rework. Technologies include automated material handling, precision laser cutting, vision systems, and AI-based quality assurance.

4. Flexible & Thin-Film Innovations

Roll-to-roll CIGS thin-film modules, like Flisom, produce lightweight, flexible panels for BIPV and mobile applications. Inkjet-printed perovskite cells enable fast, low-cost solar production. Solar modules deployed on water bodies reduce land use, minimize heating, and improve efficiency.

Sustainability in Solar Module Manufacturing

Sustainability in solar module manufacturing is becoming a necessity as the demand for clean energy grows. Leading manufacturers are increasingly using recycled materials like silicon, glass, and aluminum, reducing their dependency on virgin resources. European companies have managed to recover up to 95% of materials from decommissioned solar panels. Design innovations, such as recyclable backsheets and frameless modules, promote a circular economy.

Manufacturing facilities now operate on clean, renewable power sources like solar and wind energy, contributing to a significant reduction in operational emissions. These factories often adhere to international certifications such as ISO 50001, demonstrating commitment to energy efficiency and reduced carbon output. Water usage is optimized through closed-loop and zero-liquid-discharge systems, and innovative cleaning techniques minimize the use of water and chemicals during production.

Advanced recycling technologies allow for the recovery of critical materials with up to 99.3% efficiency, using as little as 1 kWh per panel. Modern solar factories leverage robotics, artificial intelligence, and digital twins to ensure lean production and reduce production waste by over 30%.

Certifications and compliance with regional and international standards are key indicators of sustainability in manufacturing. Opting for sustainably manufactured solar modules helps companies reduce their Scope 3 emissions, strengthens ESG performance, and aligns with global climate and compliance goals.

Solar Module Manufacturing in India: Opportunities and Growth

India is rapidly emerging as a global hub for solar module manufacturing, fueled by progressive policies, rising domestic demand, and a strategic vision of becoming self-reliant in clean energy. With over 300 sunny days a year and a national commitment to achieving 500 GW of non-fossil fuel capacity by 2030, the country is firmly positioned at the forefront of a clean energy revolution. Over the past few years, India’s solar module manufacturing capacity has seen exponential growth, led by major players such as Adani Solar, Waaree, Vikram Solar, RenewSys, Tata Power Solar, and the Reliance Giga Complex—all actively investing in state-of-the-art production lines.

The Indian government has played a catalytic role in this transformation, with the landmark Production Linked Incentive (PLI) Scheme committing ₹24,000 crore across two phases. Designed specifically to support integrated solar module manufacturing—from polysilicon to modules—the scheme aims to create 48 GW of capacity by 2026 and has already attracted ₹41,000 crore in private sector investment. Additional policy initiatives, including the Basic Customs Duty (BCD) of 40% on modules and 25% on cells, the Approved List of Models and Manufacturers (ALMM), and the development of Solar Parks and SEZs, further strengthen India’s solar module manufacturing ecosystem.

India’s emergence as a trusted alternative in the global solar supply chain is already evident, with exports to the United States alone crossing $1.8 billion in FY 2024. Today, Indian solar module manufacturing is evolving from simple assembly lines to centers of innovation. Manufacturers are adopting AI-driven automation, robotics, and next-generation technologies like HJT, TOPCon, and bifacial panels. There is also a growing focus on recyclable, eco-friendly module designs and indigenous R&D for higher efficiencies and cost optimization.

Looking ahead, industry forecasts predict that India’s solar module manufacturing capacity will exceed 125 GW by 2029—well above projected domestic demand—unlocking new opportunities for export-led growth. However, to achieve full energy independence, the nation must also scale upstream capabilities, transition to renewable-powered factories, develop a highly skilled workforce, and establish robust international logistics infrastructure.

Challenges in Solar Module Manufacturing

1. Upstream Supply Chain Dependency

  • India’s heavy reliance on imports for upstream materials like polysilicon, ingots, wafers, and cells, primarily from China, weakens supply-chain resilience and exposes manufacturers to geopolitical risks, price volatility, and trade restrictions. This lack of domestic capacity for critical raw materials, including “Made-in-India” modules, undermines supply chain resilience and exposes manufacturers to global price fluctuations.

2. High Capital Costs for Vertical Integration

  • The cost of solar modules, including cells, is significantly impacted by fluctuating prices for materials like wafers and EVA, along with inefficient inventory management. Developing fully integrated solar manufacturing facilities requires significant capital investment, limiting the number of vertically integrated players in India, slowing down the Atmanirbhar Bharat vision.

3. Technology Gaps & R&D Deficit

  • Indian manufacturers are lagging in advanced technologies like TOPCon, HJT, and bifacial cells due to limited in-country R&D and innovation capabilities. Most advanced tech is imported or licensed, hindering cost-competitiveness and self-reliance. The lack of investment in local innovation, testing infrastructure, and talent development restricts India’s ability to create next-gen modules independently.

4. Energy Intensity & Power Costs

  • India’s high industrial electricity tariffs, particularly in polysilicon purification and wafer slicing, make solar cell production highly energy-intensive, making it difficult to achieve price parity and sustainability in the industry. This is due to the lack of reliable access to low-cost, clean energy.

5. Logistics, Infrastructure & Land Acquisition

  • Manufacturing plants require logistics support, including well-connected ports, reliable land, water, and power. Acquisition delays and state-level regulations disrupt timelines and increase costs. Indian industrial zones are developing these essentials, and bureaucratic delinquency hinders their development.

6. Talent & Workforce Shortage

  • India faces a skills gap in advanced solar manufacturing, particularly in precision manufacturing, robotics, and semiconductor-grade material handling due to a lack of specialized training institutes and R&D collaboration between industry and academia, and a lack of training infrastructure for downstream and upstream processes.

The solar module manufacturing industry is experiencing a significant technological revolution, with companies like First Solar and UbiQD developing copper-indium quantum dot coatings to enhance energy output from reflected light. New cell architectures like TOPCon, Heterojunction, and perovskite-silicon tandem cells are pushing module efficiencies to unprecedented levels. Design evolution is also transforming solar modules, with bifacial modules being increasingly adopted in utility-scale and ground-mounted systems. Building-integrated photovoltaics (BIPV) is leading to transparent and aesthetic modules that blend into building facades, skylights, and windows.

Automation, artificial intelligence, and digital twin technologies are reshaping solar manufacturing lines, improving yield, reducing costs, and shortening production timelines. Cooling innovations and material substitutions are also gaining traction, with passive cooling systems and phase-change materials managing thermal loss and copper-based contacts reducing dependence on costly materials. Localized and modular manufacturing plants are being developed across regions to decentralize production and create resilient supply chains. The solar industry is expanding its footprint through flexible modules and floating solar farms, offering more efficient, durable, and customizable solar solutions.

Why Choose Soleos Solar for Solar Module Solutions

At Soleos Energy Private Limited, we stand at the forefront of India’s clean energy revolution by delivering trusted, high-performance solutions powered by the latest in solar module manufacturing. With over 12 years of experience and a strong presence across India, Europe, the UK, UAE, and Africa, we partner with industry-leading manufacturers who specialize in cutting-edge solar module manufacturing technologies like TOPCon, HJT, and bifacial panels. Our global clients benefit from efficient, durable, and environmentally responsible modules designed to meet the unique demands of commercial and industrial applications.

As the demand for quality and speed grows, our deep integration with India’s rapidly growing solar module manufacturing ecosystem allows us to offer faster delivery, superior technical support, and complete compliance with green certifications. Whether it’s for ground-mounted projects, rooftop installations, carports, or agrivoltaics, Soleos ensures every project is powered by the excellence of advanced solar module manufacturing—driving energy efficiency, ROI, and sustainability for your business.

Government Initiatives Supporting Solar Module Manufacturing

The Indian government has implemented a proactive policy ecosystem to accelerate solar module manufacturi ng, aiming to reduce import dependence, spur economic growth, and meet climate targets. Key initiatives include:

1. Production-Linked Incentive (PLI) Scheme
Launched in two tranches, the PLI scheme is a cornerstone effort to bolster solar module manufacturing.

  • Tranche I (₹4,500 cr) and Tranche II (₹19,500 cr) allocate incentives to developers of integrated solar PV modules, covering polysilicon, wafers, cells, and module production.
  • Under Tranche II, nearly 39.6 GW of domestic module manufacturing capacity has been sanctioned, supported by ₹14,007 cr investment, and expected to generate over 100,000 jobs.
  • This initiative reinforces India’s push to become self-reliant in solar module manufacturing, reduce yearly import bills by ₹17,500 cr, and achieve economies of scale .

2. Basic Customs Duty (BCD) & Domestic Content Requirements

  • A BCD of 40% on modules and 25% on cells, later reduced to 20% each in the 2025–26 Union Budget, shields domestic manufacturers from cheaper imports.
  • Alongside Domestic Content Requirements (DCR) and the Approved List of Models and Manufacturers (ALMM), these policies mandate the procurement of domestically produced solar PV modules and cells for public clean-energy projects.

3. National Solar Mission & MNRE Schemes

  • India’s National Solar Mission, launched in 2010, set initial targets for solar capacity and laid the foundation for large-scale solar parks and manufacturing ecosystems.
  • Ongoing MNRE schemes—such as the PM Surya Ghar Muft Bijli Yojana, Pradhan Mantri Kisan Urja Suraksha evam Utthaan Mahabhiyaan (PM-KUSUM), and central PSU initiatives—farm-in procurement policies that prioritize India-made modules and cells, driving local demand.

4. Infrastructure & Sectoral Support

  • Investments in solar parks, SEZs, and logistics improvements (including PM GatiShakti initiatives) support streamlined land acquisition and supply chain efficiency.
  • Financial backing from agencies like IREDA provides loans and grants specifically for solar module manufacturing projects

Conclusion

India’s journey in solar module manufacturing is entering an exciting new phase. With over 70 GW of module capacity now installed—up from just 2 GW a decade ago—thanks to game-changing government initiatives like the PLI scheme, Basic Customs Duty adjustments, and infrastructure support, India is emerging as a formidable clean energy force. Major investments, such as SAEL’s ₹8,200 cr mega-facility in Greater Noida to produce 5 GW of cells and modules annually, further underscore India’s commitment to self-reliance and global competitiveness.

However, to fully realize India’s clean energy potential, it’s essential to address critical challenges like dependence on upstream imports, high energy costs, and skill shortages. With combined efforts from policy, industry, and innovation, these bottlenecks are being tackled to build a resilient and future-ready solar manufacturing ecosystem.

Soleos Energy offers Next-Gen solar PV solutions manufactured in India, aligned with PLI incentives and green energy mandates. Equipped with high-efficiency technologies, these solutions are supported by local logistics and technical service. Partnering with Soleos ensures commercial or industrial projects utilize India’s solar module manufacturing boom’s full potential.

Soleos

5 Game-Changing Trends in Solar Panel Manufacturing in India

Posted on by Soleos
Solar Panel Manufacturing
14
Jul

India’s energy landscape is undergoing a revolutionary shift. With the push toward decarbonization and energy independence, solar panel manufacturing in India has emerged as a strategic pillar for the country’s renewable energy goals.

At Soleos Solar Energy Private Limited, we’ve witnessed this transformation firsthand. From powering rooftops to building mega solar parks, the role of indigenous solar panel production is now more critical than ever. This blog explores everything you need to know about the solar manufacturing ecosystem in India—from growth trends and policies to market players and future outlook.

Introduction to Solar Panel Manufacturing

Solar energy is a key player in the global renewable energy movement, with solar panels being a key technology. Solar panel manufacturing involves a complex process that transforms raw materials, mainly silicon, into efficient energy-generating modules. This process involves engineering, chemistry, and innovation, from refining quartz to assembling intricate PV cells. As global demand for solar panels increases, manufacturers aim to enhance efficiency, cut costs, and ensure reliability in large-scale industrial and commercial applications.

Why Solar Panel Manufacturing in India Matters

1. Strengthening Energy Security & Supply Chain Resilience: India aims to reach 364 GW of solar PV capacity by 2032, largely reliant on imports, with 80% of polysilicon, wafers, cells, and modules coming from China, reducing global supply disruptions.

2. Advancing Self‑Reliance & Geopolitical Independence: Indian conglomerates like Adani and Reliance are investing in vertically integrated supply chains to reduce their dependency on China amid geopolitical tensions.

3. Spurring Domestic Investment & Industrial Growth: The PLI scheme, worth ₹24,000 crore, is boosting domestic capacity, with states like Gujarat, Maharashtra, and Haryana constructing new hubs and gigafactories to establish a robust ecosystem.

4. Generating Employment & Economic Value: Solar manufacturing is projected to create over 500,000 jobs by 2030, with clean-tech industries offering higher average incomes than other sectors.

5. Minimizing Carbon Footprint & Promoting Sustainability: Domestically producing panels reduces carbon emissions from imports, supporting India’s net-zero target by 2070, and promotes stronger environmental standards and greener production methods.

A Brief History of Solar Manufacturing in India

1. Early Beginnings (1990s–2009)

  • India’s solar panel production began in the early 1990s with Tata BP Solar, which set up one of the country’s first solar module manufacturing units in 1991. The company’s entry into the market was driven by small pilot projects and government research initiatives. In the late 1990s, solar modules were primarily used for remote telecommunications and rural electrification, with limited market traction due to high costs and low awareness. Emvee Group entered the PV module space in 2006-07.

2. National Mission & Capacity Surge (2010–2014)

  • The Jawaharlal Nehru National Solar Mission, launched in 2010, aimed to achieve 20 GW of solar capacity by 2022, later revised to 100 GW. The mission mandated domestically manufactured cells/modules, accelerating India’s solar manufacturing landscape. The mandated use of India-manufactured cells/modules in certain projects sparked a wave of new manufacturing plants across Gujarat, Tamil Nadu, and Andhra Pradesh, marking India’s transition from solar deployment to production.

3. Growth and Global Entry (2015–2019)

  • Indian manufacturers, including Vikram Solar, Waaree Energies, and Adani Solar, increased their manufacturing capacity by nearly 10 GW by 2019, focusing on polycrystalline modules and increasing investment in monocrystalline technologies. This led to India becoming both a solar developer and hardware producer. Vikram Solar, established in 2005, launched module manufacturing in 2009, scaling to 500 MW by 2015 and expanding internationally. In February 2017, Tata Power Solar shipped over 1 GW of modules globally.

4. Strategic Policy Push & Capacity Ramp‑Up (2020–2023)

  • India launched the Production Linked Incentive (PLI) scheme in 2021 to boost high-efficiency solar manufacturing, including modules, cells, and wafers. Tariffs like Basic Customs Duty and the Approved List of Models & Manufacturers (ALMM) protected and incentivized domestic industry. These policies led to a capacity doubling, with India producing approximately 6.6 GW of cells and 38 GW of modules by 2023. The policies addressed global supply chain issues and over-reliance on Chinese imports, resulting in domestic manufacturing surges and new entrants integrating backwards. India’s solar module capacity crossed 38 GW by 2023.

5. Rapid Scale and Technological Shift (2024–2025)

  • India is preparing to become a global solar manufacturing hub, with several companies launching integrated gigafactories for polysilicon modules in Jamnagar, Gujarat. Adani Solar is expanding its value chain, while Emvee and Vikram Solar are investing in TOPCon and bifacial technologies. By 2025, India is expected to become the second-largest solar panel manufacturing hub globally, with module capacity exceeding 100 GW. Local manufacturers like Emvee have scaled aggressively, reaching 4.6 GW module capacity and adding 2.5 GW of high-efficacy TOPCon cell production by 2024. Reliance’s Jamnagar Giga Complex began its first phase in 2021.

Current Landscape of Solar Panel Manufacturing in India

1. Massive Capacity Expansion

India’s module and cell production capacity reached nearly 91 GW by the end of 2024, with Gujarat, Tamil Nadu, Rajasthan, and Karnataka being the leading states. UN estimates suggest module capacity will exceed 100 GW as PLI-supported projects come online, while cell capacity is set to surpass 50-55 GW by FY 2027. India added 25.3 GW of module and 11.6 GW of cell capacity, boosting total module output to approximately 90.9 GW and cell capacity to 25 GW+ by the end of the year. As of March 2025, module capacity surged from 38 GW to 74 GW, and cell capacity tripled from 9 GW to 25 GW.

2. Leading Hub States & Gigafactories

Gujarat leads in module capacity and cell output, with 42% of module capacity and 37% of cell capacity. Tamil Nadu hosts Tata Power’s new 4.3 GW integrated factory, while Sonipat hosts HVR Solar’s 2 GW N-type TOPCon bifacial plant. Maharashtra’s Butibori site produces 720 GW TOPCon modules, scaling from 1.5 GW to 7 GW by July 2025. Reliance’s Jamnagar Giga Complex targets 20 GW of modules with integrated cells and battery packs. Gujarat leads in module capacity and cell output, while Tamil Nadu hosts Tata Power’s 4.3 GW module-cell factory.

3. Key Players & Technology Trends

The technological split in solar energy is predominantly monocrystalline PERC (59%), with a 28% TOPCon capacity. Emerging HJT and large-format panels are becoming more common. Emvee Group has a 6.6 GW module capacity and a 2.5 GW TOPCon cell capacity, while Vikram Solar reaches 3.5 GW. Waaree is expanding its 5.4 GW cell plant and producing modules globally.

4. Government Policy Fueling Growth

The PLI Scheme, worth INR 24,000.0, supports around 48 GW of integrated modules and creates 11,650 jobs. The ALMM enforces over 64 GW of domestic module use in government projects. Adjusted import duties reduce raw material costs and protect domestic manufacturers.

Installed Manufacturing Capacity (2025 Estimates)

Component TypeInstalled Capacity (2025 Estimate)
Solar Module~90.9 GW (by end of 2024)
Solar Module~74 GW (as of March 2025)
Solar Cell~25 GW
Ingot-Wafer~2 GW
Target by 2030160 GW module & 120 GW cell capacity

Government Support & Policies Promoting Manufacturing

1. PLI Scheme (Production-Linked Incentive)

India has allocated ₹24,000 crore to boost GW-scale solar module production through a two-tiered initiative. The first tranche, awarded ₹4,500 crore in late 2021, aimed to increase capacity from 8.7 GW to 39.6 GW. The second tranche, approved in September 2022, aimed to increase capacity from 19,500 crore to 39.6 GW. The initiative aims to incentivize high-efficiency and integrated manufacturing, resulting in a surge in India’s solar module capacity from 2 GW to 70 GW in just 10 years.

2. Basic Customs Duty (BCD)

To strengthen India’s solar panel manufacturing ecosystem, the government introduced Basic Customs Duty (BCD) in April 2022—imposing 40% on solar modules and 25% on solar cells. This strategic move aimed to reduce import dependency and promote domestic solar panel manufacturing. In subsequent budgets, the BCD structure was slightly adjusted to ease access to upstream materials while still safeguarding local industries.

These measures have significantly enhanced the competitiveness of Indian-made products, giving a strong boost to solar panel manufacturing across the country. By limiting low-cost imports and incentivizing local production, India is paving the way for scalable and self-reliant solar panel manufacturing. As a result, solar panel manufacturing in India is not only expanding rapidly but also becoming more technologically advanced and globally competitive.

3. ALMM (Approved List of Models & Manufacturers)

The ALMM policy mandates solar projects from government schemes or DISCOMs to use Indian ALMM-listed manufacturers. As of 2025, 64.6 GW of module capacity is ALMM-approved, prioritizing domestic manufacturers for utility-scale and rooftop projects. Launched in 2022-2024, it ensures compliance and strengthens domestic supply.

4. Financial Support via IREDA

The Indian Renewable Energy Development Agency (IREDA) provides financial support for solar cell and module manufacturing projects, including long-term loans, soft interest rates, and custom-designed financial instruments for MSMEs and large-scale producers. With its “Navratna” status in 2024, IREDA’s capacity to support solar infrastructure is further strengthened.

Leading Solar Panel Manufacturers in India

Here are some of the key players driving solar panel manufacturing in India:

1. Soleos Solar Energy Private Limited

  • Soleos is a leading solar panel supply company with a portfolio of over 450 MW commissioned and 160 projects completed. They specialize in high-quality solar panel supply for various applications, including rooftops, ground-mount systems, solar parks, carports, and agrivoltaics. Soleos is a turnkey partner offering EPC, module sourcing, and 25-year O&M.

2. Tata Power Solar

  • Tata Power Solar, a pioneer in Indian solar manufacturing, has a 30+ year legacy and a manufacturing capacity of over 1.2 GW of modules and 4.3 GW of cells. The company is based in Bengaluru, Karnataka, and has a strong legacy in EPC expertise and government project experience. With a 4.3 GW cell-making plant in South India, Tata Power Solar is known for producing high-efficiency mono-PERC modules. The company’s Bangalore facility is among the most technologically advanced in the country.

3. Adani Solar

  • Adani Solar, a subsidiary of Adani New Industries Ltd., is a prominent Indian solar manufacturing company with a capacity of 4 GW of modules and cells, with plans to expand to 10 GW by 2027. The company operates one of India’s largest integrated solar PV manufacturing plants, with in-house polysilicon and wafer manufacturing capabilities. Adani Solar is one of the few globally integrated solar manufacturers, ensuring quality and cost efficiency. The company operates a fully integrated plant from ingot to module, setting it apart from other solar manufacturing companies.

4. Waaree Energies

  • Waaree Energies, a leading Indian solar manufacturing company, has a 12 GW capacity of modules and 5.4 GW of cells. Headquartered in Mumbai, it offers solar modules ranging from 10W to 600W. Recognized as a Tier-1 Bloomberg NEF manufacturer, Waaree leads in innovation and global reach. The company uses Mono-PERC, bifacial, and N-Type TOPCon technologies. With a large export footprint and PVEL recognition, Waaree is India’s largest solar module manufacturer.

5. Vikram Solar

  • Indian manufacturer offers 3.5-4.5 GW modules with innovative HJT, n-type modules, Tier-1 and PVEL “Top Performer” technologies. Headquartered in Kolkata, they have planned cell capacity of 3 GW and offer high-quality export-ready modules.

The Supply Chain of Solar Panel Manufacturing in India

1. Raw Materials & Inputsials

  • The key components of silicon-based solar cells include polysilicon, wafers, glass, encapsulants, backsheet, aluminum frames, and silver paste and junction boxes. India currently imports 100% of polysilicon and 80% of wafers, mainly from China and Southeast Asia, while solar glass, frames, and some encapsulants are manufactured locally. Companies like Borosil Renewables, RenewSys, and Visaka Group are expanding domestic production. The PLI Scheme incentivizes domestic manufacturing of wafers, ingots, and polysilicon.

2. Wafer to Cell to Module

  • India’s wafer production is limited, relying heavily on imports. Adani, Vikram, and Waaree are setting up wafer lines under PLI Phase-II. Solar cell manufacturing is expected to reach 20 GW by 2025, using mono-PERC, TOPCon, and HJT technologies. Major players include Adani Solar, Waaree, Vikram Solar, Avaada, Tata Power, and RenewSys.

3. Solar Module Assembly

  • India’s solar module manufacturing capacity is over 64 GW as of 2025, with major players like Waaree, Adani, Vikram, Emmvee, Rayzon, Goldi, and Soleos Solar offering high-wattage, ALMM-listed, and PVEL-certified modules. The assembly process includes cell tabbing, stringing, lamination, framing, junction box attachment, and flash testing.

4. Logistics & Distribution

  • Solar panels are bulky and fragile, requiring careful handling in manufacturing hubs like Gujarat, Maharashtra, Tamil Nadu, and Karnataka. Challenges include port dependency and interstate logistics bottlenecks. Opportunities include dedicated solar parks and green corridors.

5. Soleos Solar’s Integrated Role in the Supply Chain

  • Soleos Solar Energy is a leading EPC and solutions provider that plays a crucial role in the solar value chain. They partner with Tier-1 ALMM-approved panel manufacturers, manage BOS (balance of system), offer custom EPC solutions, and offer 25-year performance monitoring and asset management. With over 450 MW delivered and 160 projects completed, Soleos bridges solar manufacturing with end-user success, ensuring timely delivery, optimized performance, and cost-efficiency.

Challenges in Solar Panel Manufacturing in India

While the growth is promising, the industry also faces some key challenges:

1. Overdependence on Imports for Critical Raw Materials

India’s solar panel manufacturing sector, despite progress, heavily relies on imported components like polysilicon, wafers, silver paste, and specialized chemicals, making it highly sensitive to international price volatility, trade tensions, and currency fluctuations, unless robust upstream capacity is built.

2. Lack of Full Vertical Integration

India has made significant strides in module assembly, but the solar panel manufacturing value chain still lacks domestic wafer production, sufficient polysilicon refining, and seamless ingot-to-module integration. Most Indian manufacturers import intermediate products, limiting efficiency, quality control, and cost competitiveness.

3. Technological Gaps

India has made significant strides in module assembly, but the solar panel manufacturing value chain still lacks domestic wafer production, sufficient polysilicon refining, and seamless ingot-to-module integration. Most Indian manufacturers import intermediate products, limiting efficiency, quality control, and cost competitiveness.

4. High Capital Costs and Infrastructure Gaps

Solar panel manufacturing faces significant capital constraints due to high interest rates, expensive industrial land, and limited infrastructure in Tier-2 and Tier-3 regions, making it difficult for many units to scale without better financing access and industrial support.

5. Logistics Challenges

India faces challenges in transporting raw materials and modules, including high costs, congested ports, and customs clearance delays, impacting solar panel manufacturing timeline and profitability, particularly for export-focused players.

6. Global Competition and Price Pressures

Indian solar panel manufacturing companies face intense competition from Chinese and Southeast Asian firms, who operate on large scales, receive government subsidies, and offer aggressive global pricing, potentially causing them to struggle in international markets.

Role of Soleos Solar in India’s Manufacturing Ecosystem

Soleos Solar Energy is a key player in India’s solar panel manufacturing industry, serving as a bridge between Tier-1 manufacturers and large-scale deployments. They source high-efficiency modules from domestic manufacturers like Waaree, Adani, and Vikram, ensuring cost-optimization and regulation compliance. As a full EPC provider, Soleos oversees engineering, procurement, construction, and quality control. With logistics hubs across India and international reach, they facilitate seamless execution for rooftop, ground-mount, and solar park projects. They also integrate next-gen technology and provide 25-year O&M services with real-time SCADA monitoring.

Future of Solar Panel Manufacturing in India

India’s solar panel manufacturing industry is on the brink of transformation, driven by rising energy demand, government incentives, and a global push for clean energy independence. With a projected growth in manufacturing capacity of 100 GW by 2026, India’s solar module manufacturing capacity is expected to reach 55 GW or more. Companies like Adani Solar, Waaree Energies, Vikram Solar, Tata Power Solar, and Soleos Solar are at the forefront of this manufacturing boom. India’s next phase of solar manufacturing will be marked by a shift from conventional PERC modules to advanced technologies like n-type TOPCon, HJT, and bifacial solar panels.

Major manufacturers are scaling aggressively, with Adani Solar targeting 10 GW of integrated module and cell production, Waaree Energies commissioned a 12 GW plant, Vikram Solar and Tata Power Solar ramping up capacity with high-efficiency bifacial modules and smart manufacturing lines. India’s policy ecosystem strongly favors domestic solar panel manufacturing, with key enablers including the Production Linked Incentive Scheme, ALMM Mandate, Basic Customs Duty, and National Green Hydrogen Mission & Rooftop Solar Incentives.

Key Takeaways for Manufacturers and Industry Leaders

  1. India is Set to Become a Global Solar Manufacturing Powerhouse
    With projected capacity reaching 100+ GW for modules and 55+ GW for solar cells by 2026, India is well on its way to becoming a major player in global solar panel manufacturing.
  2. Advanced Technologies Are the Future
    Manufacturers must pivot toward TOPCon, HJT, and bifacial modules to stay competitive. R&D in perovskite tandem cells and high-wattage modules (700+ Wp) will define the next wave of growth.
  3. Policy Support is a Strong Tailwind
    The PLI scheme, ALMM mandates, and BCD tariffs are boosting domestic manufacturing viability. Leveraging these policies is essential for long-term profitability and eligibility for government-backed projects.
  4. Export Markets are Ripe for Expansion
    With growing demand in the USA, Europe, MENA, and Africa, Indian manufacturers—especially those compliant with IEC standards—have an opportunity to capture significant global market share.
  5. Vertical Integration is a Competitive Advantage
    Investing in end-to-end production (from wafers to modules) ensures cost efficiency, quality control, and resilience against global supply chain shocks.
  6. EPC and Supply Chain Partnerships Matter
    Collaborating with EPC leaders like Soleos Solar, who bridge manufacturing and field execution, ensures smoother deployment, faster time to market, and optimized project performance.
  7. Talent and Skilling are Critical
    The shift to high-tech manufacturing requires a skilled workforce. Investing in training, automation, and process innovation is essential to support scale and quality.
  8. Sustainability is a Differentiator
    Manufacturers integrating green production practices, circular recycling programs, and lower carbon footprints will attract ESG-conscious investors and customers.

Conclusion: The Bright Future of Solar Panel Manufacturing in India

India’s solar panel manufacturing sector is poised for a promising future, driven by innovation, government support, and a commitment to sustainability. As the country aims for clean energy targets, solar panel manufacturing is becoming a crucial pillar in achieving energy independence, reducing carbon emissions, and positioning India as a global leader in renewable technology. Progressive policies like the Production Linked Incentive scheme, ALMM mandates, and Basic Customs Duty tariffs are empowering local manufacturers to scale operations, adopt advanced technologies, and strengthen the solar supply chain.

Companies like Adani Solar, Waaree Energies, Vikram Solar, and Soleos Solar are redefining the landscape of solar panel manufacturing in India, enhancing the quality and reliability of solar modules while contributing to India’s capability to serve both domestic and international markets. Despite challenges like raw material imports, logistics constraints, and skill shortages, the sector continues to grow, supported by consistent policy support and increasing investments in research and development. With rising global demand for clean energy technologies, India has the opportunity to become a global exporter of high-efficiency, cost-effective solar solutions. With the right mix of technology, talent, and policy, India is on course to lead the world in solar panel manufacturing, powering progress for generations to come.

FAQs

1. What is solar panel manufacturing, and why is it important in India?

Solar panel manufacturing refers to the process of producing photovoltaic (PV) panels, which convert sunlight into electricity. In India, this sector is crucial to reducing reliance on imports, achieving clean energy goals, creating jobs, and establishing the country as a global renewable energy hub.

2. Who are the leading solar panel manufacturers in India?

India hosts several prominent manufacturers, including Waaree Energies, Adani Solar, Vikram Solar, Tata Power Solar, RenewSys, Emmvee, and Soleos Solar, each contributing significantly to India’s solar manufacturing capacity and technological advancement.

3. What technologies are used in solar panel manufacturing in India?

Indian manufacturers are transitioning from traditional mono PERC to advanced technologies such as TOPCon (Tunnel Oxide Passivated Contact), HJT (Heterojunction Technology), bifacial modules, and perovskite tandem cells, aimed at improving efficiency and output.

4. What is the current manufacturing capacity for solar panels in India?

As of 2025 estimates, India’s solar panel manufacturing capacity exceeds 100 GW for modules and 55 GW for cells, with major expansions underway under the PLI (Production Linked Incentive) scheme.

5. How is the Indian government supporting solar panel manufacturing?

The Indian government has introduced several initiatives, including:

  • PLI Scheme to incentivize capacity additions and technology upgrades
  • ALMM (Approved List of Models and Manufacturers) compliance for public projects
  • 25%–40% BCD tariffs to reduce cheap imports and promote local production
  • Subsidies for rooftop solar, indirectly boosting domestic demand

6. Is India exporting solar panels to other countries?

Yes. Indian solar panel manufacturers are increasingly exporting to the USA, Europe, Middle East, and Africa. With rising global demand and the “China+1” sourcing strategy, India is emerging as a reliable exporter of quality solar modules.

7. What role does Soleos Solar play in the manufacturing ecosystem?

Soleos Solar acts as a critical bridge between solar panel manufacturing and real-world deployment. While not a primary manufacturer, Soleos partners with ALMM-listed brands to source high-quality panels, integrating them into turnkey EPC solutions for industrial, commercial, and utility-scale projects across India and abroad.

8. What are the major challenges in solar panel manufacturing in India?

Key challenges include:

  • Dependence on imported raw materials like polysilicon and wafers
  • High capital investment required for upstream integration
  • Skill shortages in advanced manufacturing and R&D
  • Logistics and infrastructure limitations in remote areas

9. What are the future trends in solar panel manufacturing in India?

The future is geared toward:

  • Advanced cell technologies (TOPCon, HJT, perovskite)
  • Fully integrated supply chains (from polysilicon to modules)
  • Digital manufacturing and AI-driven QC
  • Sustainable and recyclable modules to support ESG goals
  • Export growth with compliance to international standards (IEC, UL, etc.)

10. How can manufacturers or EPC companies partner with Soleos Solar?

Manufacturers and EPC providers can collaborate with Soleos Solar for:

  • Module procurement aligned with ALMM/PLI policies
  • Turnkey EPC execution across C&I, utility, and solar park projects
  • Long-term O&M and digital asset management
  • Market entry support in global regions including the UAE, UK, Kenya, and Spain