Effects of Changing Wafer Sizes on Solar Module Manufacturers Mr. Ankit Singhania, Director & Co-founder, Navitas Solar – EQ Mag Pro

Solar Industry has witnessed significant changes in module manufacturing in the past few years with the introduction of new technologies like half cut, triple cut, PERC, bifacial, HJT etc. All the manufacturers have come a long way in the wafer size shift from M2 to G12. Since 2018, M2 (156.75 mm dimension) size wafers were having a significant share in the solar wafer market and it ruled the market for past 10 years.

Then M3 (158.75 mm) came into market followed by M4 (161.7 mm) in 2019. When M6 (166 mm) entered the market, it was accepted as a standard in later 2019. Mostly, manufacturers talk about lower LCOE and high ROI for the developers because of large sized wafers but in this article, we will be discussing about the effects of changing wafer sizes on solar module manufacturers. In shifting the wafer size from M2 to G12, manufacturers are supposed to buy new machineries and for the same they required a huge capital.

When wafer sizes are changed, many items associated with it are also changed like cell line manufacturing machineries, back sheet size, EVA sheet size, ribbon, glass etc. The change in associated items causes many issues, which are not discussed often. When raw materials are changed, it is essential that RM inventories are also upgraded and that require huge efforts.

Nowadays, many manufacturers adapt M10 (182 mm) size and G12 (210 mm) size wafers and looking at the current scenario, we believe that M10 size wafers will be the choice of the consumers in upcoming time. A few top players in the industry started to produce M6 size modules but it will take a long time to shift to M10 & G12 sizes. In future if only G12 size wafers are available, then all the domestic manufacturers have to shut down their existing plant and buy new machineries only for producing G12 size modules. Many companies may not handle that financial jerk, especially MSMEs. There is a need of standardization in the module manufacturing industry. When the wafer sizes are advanced, either the entire set up needs to be changed or existing setup can be used with the technical upgradations. In the second option, productivity may suffer a bit. Every new technology will require certain amount of changes and those changes are essential to be adapted by manufacturers to be in the market.

Back then in 2019, it was firmly believed that M6 would remain as the largest wafer size for some time. However, soon M10 and G12 were launched which has taken over M6. It will certainly require some time for leading module manufacturers to adapt the new size completely because every transition takes its own time. Currently, the domestic manufacturing companies are well equipped to deal the minor modifications but for wafers larger than 182 mm, many modifications are required. Manufacturing modules of 182 mm size and beyond, new equipment are needed and that will cost a lot of money.

We feel that technological evolution is inevitable and it has to happen for the sector’s development. Although, many issues are associated along with it which every manufacturer has to deal. Technology has to be continuously upgraded and that will help to increases module’s efficiency, reduce the balance of system (BOS), and lead to lesser land usage. Our industry is showing good signs of developing RM inventory especially in glass, EVA sheet, ribbon, back sheet & junction boxes. The whole ecosystem of RM in this sector has seen a good growth and even many players are coming future. We ourselves are also having our backward integration as we have our own EVA sheet-manufacturing unit with the capacity of 750 MW per annum and we are expanding it to about 2 GW in couple of months. The new players are coming aggressively in the market of raw materials but the module manufacturers are lacking behind and struggling to meet up the expectations. We have seen a good growth in demand of high power modules, which indicates that large wafer sized modules are being adapted in the market.

“We ourselves have also installed the completely new line and we are delighted to launch Bonito series-Mono PERC Half Cut modules this year. Bonito Pro will be available in 9 BB in 166 mm cell size (M6) in 144 cells & 156 cells producing 435 to 500 Watts. Bonito Max will be available in 10 BB in 182 mm cell size (M10) in 144 & 156 cells and producing 530 to 600 Watts. We have installed fully automatic line including auto bussing in the new manufacturing facility and two lines are ready to produce M10 modules,” said Mr. Ankit Singhania. Without a local manufacturing ecosystem, manufacturers have no other choice but to continue adapting to new technologies and meet the standards that are set globally.