Technical Description

Solar Encapsulation Interlayer Film Manufacturing Plant (EVA / POE / EPE)

Capacity: ~1 GW Equivalent (8.5–10 Million m² per annum)

1. Executive Summary

This Detailed Project Report (DPR) covers the establishment of a state-of-the-art Solar Encapsulation Interlayer Film Manufacturing Plant producing EVA, POE, and EPE films used in crystalline silicon solar PV modules.

The proposed facility is designed around a GWELL/GW-type high-end extrusion line with advanced melt pumping, precision T-die, five-roll calendering, X-ray thickness measurement, and fully automated winding. The plant is sized to support ~1 GW of solar module production per annum, equivalent to 8.5–10 million m² of encapsulation film.

The project targets:

• Import substitution
• Supply to Tier-1 solar module manufacturers
• Long-term compatibility with TOPCon / HJT / N-type technologies

2. Project Objectives

• Manufacture high-quality EVA / POE / EPE solar encapsulation films
• Achieve tight thickness tolerance (±2.5%) and optical consistency
• Meet IEC / UL / TUV solar module standards
• Enable future expansion to POE-rich & co-extruded structures
• Support domestic and export markets

3. Product Description

3.1 Product Types

3.2 Key Specifications

• Width: up to 2600–3000 mm
• Thickness range: 0.4 – 1.0 mm
• Density reference: ~450 g/m² @ 0.65 mm
• Transparency: ≥91%
• Gel content (EVA): ≥80% (after curing)

4. Plant Capacity & Throughput

4.1 Line Output

• Extruder output: 700–800 kg/hour
• Operating speed:
• EVA: 8–14 m/min @ 2600 mm
• POE/EPE: 6–10 m/min @ 2600 mm

4.2 Annual Production

Assuming:

• 330 operating days/year
• 22 hours/day
• Average film grammage: 450 g/m²

5. Manufacturing Process Flow

1. Raw Material Handling (EVA / POE Pellets)
2. Precision Mixing (Conical Mixer)
3. Extrusion (GWS180/35)
4. Screen Filtration & Melt Pumping
5. Multi-layer Distribution (A/B/A optional)
6. T-Die Casting
7. Five-Roll Calendering & Embossing
8. Cooling & Stabilization
9. Online Thickness Measurement (X-ray)
10. Edge Trimming & Slitting
11. Electrostatic Elimination
12. Servo-Controlled Haul-off
13. Automatic Center Winding
14. Scrap Recycling via GWS80 Extruders

6. Major Equipment Summary

6.1 Extrusion & Melt System

• GWS180/35 Single Screw Extruders (2 Nos.)
• Plate Type Hydraulic Screen Changers
• JC-Times Melt Pumps with Water Cooling
• Closed-loop pressure control

6.2 Forming & Calendering

• Five-Roller Casting Calender (3000 mm)
• Silicone + Pattern + Cooling Roller System
• Sub-zero rubber roll cooling

6.3 Automation & Quality Control

• X-ray Thickness Gauge (with or without feedback)
• Automatic T-die lip control
• PLC–Siemens based electrical control

6.4 Winding & Finishing

• Automatic friction center winders (2 Nos.)
• Low-tension trimming & slitting system
• Electrostatic eliminators

7. Utilities Requirement

6A. Plant Layout & Area Requirement

6A.1 Main Production Line Footprint

Based strictly on the supplied installation dimensions for the complete EVA/POE/EPE extrusion line:

• Length: 25 meters
• Width: 6 meters
• Clear height required: 8 meters

Net machine footprint area:
 25 m × 6 m = 150 m²

Enclosed volume (for HVAC / fire design):
 25 × 6 × 8 = 1,200 m³

This height is mandatory to accommodate:

• T‑die head & calender stack
• Overhead cable trays
• Roller quick‑release mechanism
• Crane clearance

6A.2 Mandatory Working & Safety Clearances

For safe operation, roll handling, maintenance, and statutory compliance:

Effective operational footprint:

• Length: ~35 m
• Width: ~10 m

 Operational area per line: ≈ 350 m²

6A.3 Ancillary Areas (Same Building)

6A.4 Total Built‑Up Area Requirement (1 Line – 1 GW)

 Total recommended covered area:

 1,500 – 1,750 m²

6A.5 Structural & Civil Recommendations

• Clear internal height: ≥ 9 m (preferred 10 m)
• EOT crane provision: 10–15 MT (die + roller handling)
• Floor load bearing: ≥ 5–6 T/m² under extruder & calender
• Anti‑vibration foundation blocks for extruders

7.1 Electrical Power

• Connected load: ~550–600 kW
• Supply voltage: 415V / 50Hz / 3-phase

7.2 Water

7.3 Compressed Air

• Pressure: ≥7 bar
• Consumption: ~1 m³/hr
• Oil & moisture free

8. Manpower Requirement

Total manpower (3 shifts): 40–45 persons

9. Quality & Standards

• IEC 62788
• UL 1703 / UL 61730
• TUV Rheinland certification
• ISO 9001 / 14001

In-house testing:

• Thickness & GSM
• Optical transmission
• Gel content
• Shrinkage

10. Environmental & Safety Aspects

• No liquid effluent
• 100% edge scrap recycling
• Low VOC emission
• Noise <85 dB
• Compliance with local PCB norms

11. Project Cost Estimate

Project cost is not expressed in monetary terms in this DPR, as it varies significantly based on the final technical configuration of the production plant.

The total project investment depends on multiple interlinked technical and commercial parameters, including but not limited to:

• Production plant technical configuration and overall layout
• Selected technologies (standard vs high-end / future-ready)
• Designed output capacity (kg/hr and m²/year)
• Maximum film width (e.g. 2600 mm vs 3000 mm)
• Film thickness range and tolerance
• Grammage (GSM) specification
• Type of solar film sheet: EVA / POE / EPE
• Film structure: single-layer / co-extruded / triple-layer (A/B/A)
• Type of T-die: manual or automatic lip adjustment
• Filtration system configuration (standard / fine / multi-stage)
• Melt pump specification and pressure control philosophy
• Type of polymer distribution system
• Online thickness measurement (with or without closed-loop feedback)
• Type and level of automation in winding and roll handling
• Scrap recycling integration and reprocessing level
• Utility configuration (chillers, energy efficiency, redundancy)

Accordingly, project cost must be evaluated on a case-by-case basis after finalisation of the above parameters in discussion with equipment OEMs and technology partners.

For reference only (non-binding):
FOB equipment price depends on full A–Z technical configurations, however it may typically range from USD 650,000 up to USD 1,000,000 FOB, subject to final scope, automation level, materials, and performance guarantees.

12. Financial Highlights (Indicative)

• EBITDA margin: 18–25%
• Payback period: 4–5 years
• IRR: 18–22%

13. Implementation Schedule

Total project duration: 10–11 months

14. Risk & Mitigation

• Raw material price volatility → Long-term polymer contracts
• Technology shift to POE → Multi-product line design
• Module thickness migration → Auto T-die & feedback gauge

15. Conclusion

The proposed 1 GW EVA/POE/EPE solar encapsulation film plant is technically robust, future-ready, and commercially attractive. With advanced European–Chinese hybrid equipment configuration, the facility is suitable for supplying Tier-1 solar module manufacturers in India and global markets.