Technical Description

Complete Turnkey TOPCON‑N Solar Module Manufacturing Production Assembly Line with 1.2 GW annual capacity.

The report is technology‑focused and scope‑focused only.

The project represents a highly automated, inline solar module manufacturing facility designed for mass‑scale production of next‑generation N‑Type TOPCon modules with high yield, consistency, and traceability.

2. Project Objective

• Establish a 1.2 GW fully automated TOPCon‑N solar module manufacturing plant
• Cover complete production from cell stringing to final inspection & PDI
• Ensure high equipment efficiency (~95%)
• Enable scalability, repeatability, and export‑ready quality

3. Technology Overview

• Cell Type: N‑Type TOPCon
• Supported Cell Formats: M10 / G12R, 16 Busbar
• Module Types:
• Glass‑Glass
• Glass‑Backsheet
• Automation Level: Inline, AI‑assisted inspection, minimal manual handling

4. Manufacturing Process Flow

1. Cell stringing with automatic laser cutting and auto bussing
2. Inline visual & EL inspection with AI
3. Glass loading and EVA cutting & laying
4. Lay‑up inspection and barcode tracking
5. Auto lamination (multi‑stage)
6. Trimming, corner cutting & sealing
7. Inline EL & AOI inspection
8. Framing and junction box fixing
9. Electrical testing & sun simulation
10. Sorting, labeling, curing & PDI

5. Production Capacity

• Nominal Installed Capacity: 1.2 GW per annum
• Equipment Efficiency: ~95%
• Continuous inline operation with buffer automation

6. Plant & Environment Requirements

6.1 Environmental Conditions

• Ambient Temperature: 10°C to 35°C
• Relative Humidity: <50–60%
• Altitude: <2,000 meters above sea level

6.2 Area Requirement

• Total area requirement is customizable based on plant layout, logistics flow, and local regulations

7. Scope of Supply (Complete – Part A to Part F)

Part A – Main Production Line Equipment

1. Fully automatic cell stringing system with laser cutting, auto lay‑up, auto bussing, cell flipping, EL & VI inspection, AI‑based defect detection, automatic busbar ribbon melting, curve cutting, punching, and automatic busbar changeover
2. Automatic glass loading system (dual‑side pallet)
3. Inline EVA cutting & laying system with dual rollers and slot melting
4. Inline AOI inspection after auto bussing
5. EVA slot placement system with barcode printing and pasting on busbar
6. Automatic tape sticking machine (multi‑head)
7. Inline EVA and backsheet cutting, laying & punching system
8. Secondary glass loading system
9. Glass mixing system
10. Ribbon bending and tape placement system
11. Inline EL testing system with dual‑side visual inspection and AI
12. Automatic tape sealing machine
13. Glass loader for repair stations
14. Vertical lifting glass loader for repair operations
15. Fully automatic laminators with multi‑stage chambers, oil heating, vacuum & booster pumps, integrated lifting belts
16. Sealing tape removal system
17. Automatic edge and corner trimming machine
18. Inline EL testing system after lamination with AI integration
19. Dual‑side AOI visual inspection system
20. Fully automatic framing machine with buffer loader and dual‑head operation
21. Inter‑connector busbar lifting and tape removal system
22. Automated glue dispensing system for junction box area
23. Junction box placement system (fixed model)
24. Automatic junction box soldering system with tin adding
25. Automatic junction box potting system (multi‑nozzle)
26. Potting pump system
27. Potting inspection system including mounting hole inspection
28. Automatic corner filling system
29. Testing kit automatic loading system
30. Sun simulation testing system with top lighting and large‑area testing capability
31. Inline Hi‑Pot testing system (multi‑layer)
32. Testing kit automatic removal system
33. Final AOI visual inspection system (dual‑side)
34. Automatic labeling system for back label and frame barcode
35. Automatic corner paper fixing system

Part B – Pre‑Lamination Automation

• Multiple belt conveyors with alignment
• Buffer systems before and after critical processes
• 2‑axis and 3‑belt conveyors
• Automatic gates and manual bypass gates
• Free rotation and 90‑degree rotation conveyors
• Dedicated repair stations

Part C – Post‑Lamination Automation

• Lifters and buffer systems
• Multi‑axis conveyor transfer systems
• Flipping and turning units (90° & 180°)
• Module loaders and unloaders
• Curing line with humidifier
• Standard module storage racks
• Automatic sorting system with multi‑bin configuration
• Final inspection conveyors and test jig return lines

Part D – PDI (Pre‑Dispatch Inspection) Line

• Conveyors with alignment
• Sun simulator test station
• Hi‑Pot tester
• Inline EL inspection with AI
• Module turning systems
• Final testing extension jigs

Part F – Offline & Auxiliary Equipment

• Junction box dispenser system
• String repair EL stations
• EVA slot and Teflon cutting machine
• Lamination frames for glass‑to‑glass modules

8. Automation, Quality & Traceability

• Inline automation across entire line
• AI‑enabled EL & AOI systems
• Barcode and MES‑ready traceability
• Reduced manual handling & defect rate

9. Capital Cost Summary (Indicative)

The following high-level capital cost components are included for project reference. These costs relate strictly to equipment and system-level scope and do not include land, civil works, utilities, taxes, duties, or local statutory charges.

• Conveyor Line Control System: 60,000
• Export Sea-Worthy Packing: 75,000
• MES Software Setup (Hardware Not Included): 1,50,000

10. Manpower (Indicative)

• Highly automated plant with low operator dependency
• Operators, quality inspectors, maintenance, and engineering teams as per shift planning

11. Project Implementation Timeline (Indicative)

• Engineering & layout finalization
• Equipment manufacturing
• FAT readiness and execution
• Shipment & site readiness
• Installation, commissioning & SAT
• Trial production & ramp-up

Overall typical execution cycle aligned to 8–9 months, subject to project readiness.

12. Lead Time, Delivery & Commercial Milestones

12.1 Lead Time & FAT Schedule

• 60–75 days: Readiness for FAT of the first production line after receipt of purchase order and advance payment
• Subsequent lines: Every 30 days after first line FAT readiness
• 76–82 days: FAT execution and approval (per line)
• 83–98 days: Machine shipment to port-side warehouse for export handling

12.2 Payment Milestones (Indicative)

• 20% advance payment along with purchase order
• 60% payment prior to shipment
• 10% payment after arrival at buyer’s site
• 10% payment after SAT completion within one month, or four months from dispatch date (whichever is earlier)

13. Installation, Commissioning & Training

• Experienced engineers to be deputed for:
• On-site installation
• Commissioning & debugging
• Trial production support
• Operator and maintenance training
• Production ramp-up assistance
• Installation & commissioning support: 60 days (free of charge)
• Extended on-site technical support: Up to 90 days
• Additional training or special support, if requested, chargeable on a per engineer per day basis

Buyer to arrange:

• Hotel accommodation (minimum 3-star)
• Daily meals
• Local transportation
• Domestic air travel (round trip)
• Quarantine or statutory expenses, if applicable

14. Warranty, Service & After-Sales Support

14.1 Warranty Terms

• Warranty period:
• 12 months from SAT sign-off, or
• 16 months from shipment date (whichever is earlier)
• Equipment warranted to be free from defects in material and workmanship
• Performance to be in substantial compliance with approved specifications and operating manuals

14.2 Warranty Exclusions

• Damage due to improper operation or misuse
• Normal wear-and-tear and consumable parts

14.3 Spare Parts & Service

• Replacement parts supplied free of charge during warranty period for manufacturing defects
• Import duties or local taxes, if any, to be borne by the buyer
• Transportation cost for warranty replacement parts covered by supplier

14.4 Post-Warranty Support

• Lifetime support for maintenance, spares, and technical services on chargeable basis
• Annual Maintenance Contract (AMC) available as an optional service

15. Regulatory, Statutory & Compliance Framework

• Factory registration under applicable industrial acts
• Electrical safety, fire safety & environmental clearances
• Compliance with national and international PV module standards (IEC / BIS / UL readiness)
• Labor law, EHS and workplace safety compliance

16. Risk Assessment & Mitigation

16.1 Technical Risks

• Risk: Technology obsolescence
  Mitigation: Modular equipment design and upgradability
• Risk: Yield loss during initial ramp-up
  Mitigation: AI-based inspection, structured training, and phased ramp-up

16.2 Operational Risks

• Risk: Downtime due to utilities or spares
  Mitigation: Preventive maintenance schedules and critical spares planning

16.3 Commercial & Market Risks

• Risk: Module price volatility
  Mitigation: Focus on high-efficiency TOPCon modules and diversified markets

17. Financial Structure (Bankable Framework)

17.1 Project Cost Components

• Plant & Machinery
• Automation & Control Systems
• Installation & Commissioning
• Software & Traceability Systems
• Pre-operative Expenses
• Contingency
• Working Capital Margin

17.2 Means of Finance (Indicative)

• Promoter Equity
• Term Loan from Banks / Financial Institutions
• Subsidy / Incentives (if applicable)

17.3 Key Financial Metrics (Indicative)

• Project structured to achieve stable cash flows after stabilization period
• Debt servicing aligned with ramp-up schedule
• Adequate DSCR cushion planned through conservative assumptions

18. Operations & Maintenance Strategy

• Preventive maintenance-based O&M philosophy
• OEM-trained maintenance teams
• Critical spares inventory management
• Optional long-term maintenance contract

19. Implementation & Monitoring Framework

• Dedicated project management team
• Milestone-based execution and monitoring
• FAT, SAT and acceptance-driven payments
• MIS and KPI-based operational control

20. Environmental & Social Impact

• Non-polluting green manufacturing process
• Supports renewable energy transition
• Employment generation (direct & indirect)
• Compliance with ESG best practices