Case Study: How One Solar Factory Doubled Capacity with a TOPCon Upgrade

Many entrepreneurs who entered the solar manufacturing industry five to ten years ago now face a critical challenge: their production technology is becoming obsolete. A factory that was once state-of-the-art may now struggle to produce solar modules that compete on efficiency and price with the latest market offerings. This situation forces a difficult decision: is it better to build a new facility from the ground up, or can an existing plant be successfully modernized?

This case study examines one such project: the upgrade of an established solar module assembly plant in Indonesia. Guided by J.v.G. Technology, it details the strategic, technical, and financial considerations involved in replacing an aging PERC production line with a modern, automated line for high-efficiency TOPCon modules.

The Challenge of Outdated Production Technology

Rapid technological advancement defines the solar industry. According to the International Technology Roadmap for Photovoltaic (ITRPV), the market share of p-type PERC technology, once the industry standard, is in steep decline. Meanwhile, n-type technologies like Tunnel Oxide Passivated Contact (TOPCon) are projected to dominate, capturing over 70% of market share within the next decade.

For an existing manufacturer, this shift presents several business challenges:

• Reduced Competitiveness: Modules produced on older lines have lower power output and efficiency, making them less attractive in a crowded market.
• Lower Margins: An inability to compete on performance often forces price reductions, squeezing already thin profit margins.
• Higher Operational Costs: Older equipment is typically less automated, leading to higher labor costs, increased material waste, and lower production yields.

Facing this reality, factory owners must evolve or risk being left behind. Modernization offers a path forward without the extensive capital and time commitment of a new greenfield project.

The Brownfield Project: Upgrading an Existing Facility

A ‘brownfield’ project involves repurposing or upgrading an existing industrial site, as opposed to a ‘greenfield’ project built on undeveloped land. In solar manufacturing, this typically means replacing the core production machinery within an existing factory shell.

This approach offers significant advantages:

• Reduced Capital Expenditure: The largest costs of a new build—land acquisition, construction, and utility installation—are mostly avoided.
• Faster Time-to-Market: Modernization projects can often be completed in 9–12 months, compared to the 18–24 months typical for a greenfield build.
• Leveraging Existing Assets: The project utilizes the existing workforce, logistical infrastructure, and business permits.

However, brownfield projects require meticulous planning to overcome challenges like spatial constraints, floor load limits, and the integration of new systems with existing building utilities.

The Indonesian Manufacturer: A Scenario for Modernization

Let’s consider a typical scenario based on projects J.v.G. has consulted on. A company in Indonesia has operated a 100 MWp/year PERC solar module assembly line for seven years. The facility is well-maintained, and the staff is experienced. However, the business faces pressure from imported modules that offer higher wattage at competitive prices.

The management team concluded that a strategic upgrade was necessary. Their objective was to double capacity to 200 MWp and shift to TOPCon technology, enabling them to produce high-performance modules for commercial and utility-scale sectors in Southeast Asia. The first step involved a thorough revision of their original solar module manufacturing business plan to reflect the new technology and market goals.

The Modernization and Integration Plan

A successful upgrade depends on a structured engineering approach. Guided by J.v.G. engineers, the process was broken down into distinct phases.

Step 1: On-Site Assessment and Layout Design

Before any equipment was ordered, a technical team conducted a comprehensive audit of the existing facility. This included:

• Verifying architectural drawings and measuring floor space.
• Assessing the load-bearing capacity of the floor.
• Analyzing existing electrical, compressed air, and HVAC systems.
• Mapping the logistics for removing old machinery and delivering the new.

Based on this data, engineers designed a new production layout optimized for a modern, automated TOPCon line. The design ensured a logical workflow, minimized material movement, and fit entirely within the existing building footprint.

Step 2: Equipment Selection and Automation

The core of the upgrade was selecting new solar panel manufacturing equipment capable of handling larger n-type TOPCon cells and enabling a high degree of automation. Key machinery included:

• High-Speed Tabber Stringer: A crucial machine for soldering cells together, designed for the delicate handling of n-type cells.
• Automated Layup Station: To precisely position cell strings for lamination.
• New Generation Laminator: Capable of handling larger glass-glass or glass-backsheet modules with consistent quality.
• Electroluminescence (EL) and Sun Simulator (Flasher): Advanced quality control systems to test finished modules to the latest standards.

The focus on automation was key to reducing manual handling, which improves production consistency, lowers the risk of cell micro-cracks, and ultimately increases overall yield.

Step 3: Decommissioning, Installation, and Training

The project was carefully scheduled to minimize downtime. The process involved dismantling and removing the old PERC line section by section, followed immediately by the installation of the new equipment. This phased approach is a hallmark of well-managed turnkey solar manufacturing lines, where coordination is key.

Once installed, J.v.G. commissioning engineers calibrated each machine and trained the local Indonesian team on operation and maintenance. This knowledge transfer ensures the client’s team can manage the new, more sophisticated production line independently.

The Business Case: Investment and Return

A modernization project is ultimately a financial decision. The investment in new machinery for a 200 MW TOPCon line can range from $5 million to $7 million, depending on the level of automation and supplier choices.

The return on this investment is driven by several key improvements:

• Higher Module Prices: High-efficiency TOPCon modules (e.g., 580 Wp+) command a premium price per watt compared to standard PERC modules (e.g., 450 Wp).
• Lower Production Costs: Modern automation reduces labor requirements per module. Higher material yields—meaning less waste from cell breakage—also directly translate to a lower cost of goods sold.
• Increased Market Access: With certified, high-performance products, the company can re-enter competitive markets, including government tenders and large-scale private projects that specify the latest technology.

The project timeline, from final planning to the production of the first certified module, was estimated at 10 months, allowing the manufacturer to capitalize on market demand far sooner than a greenfield project would have.

Conclusion: A Viable Path to Renewed Competitiveness

This case study demonstrates that modernizing an existing solar factory is a highly viable strategy for established manufacturers. For a company in a region like Indonesia, with high solar irradiation and growing energy demand, upgrading to TOPCon technology provides a clear competitive edge.

By replacing an aging asset with a modern, automated production line, the manufacturer not only protects its market position but also establishes itself as a supplier of high-performance technology for the next decade. Such a brownfield project requires detailed engineering, careful planning, and experienced partners, but the reward is a faster, more capital-efficient path to market leadership.

Frequently Asked Questions (FAQ)

What is TOPCon technology and why is it important?

TOPCon (Tunnel Oxide Passivated Contact) is an advanced, high-efficiency solar cell technology. It offers higher conversion efficiency and a lower degradation rate compared to older PERC technology. As the industry moves toward more powerful modules, TOPCon has become the new standard for competitive manufacturing.

Can any existing factory be upgraded for modern solar production?

Not all buildings are suitable. Key requirements include sufficient ceiling height (typically at least 5-6 meters), adequate floor load capacity to support heavy machinery like laminators, and reliable access to industrial-grade utilities (power, compressed air). A professional site assessment is an essential first step.

How many employees are needed for an automated 200 MW line?

A modern, semi-automated 200 MW production line typically requires 80 to 100 people to run a 24/7 operation, spread across three shifts. This includes operators, quality control technicians, maintenance staff, and logistics personnel.

Is it always better to upgrade than to build a new factory?

Upgrading (a brownfield project) is often faster and less capital-intensive, provided a suitable building is already available. However, if the existing facility has significant limitations in size or infrastructure, or if the goal is a much larger capacity (e.g., gigawatt-scale), a new greenfield project may be the more logical long-term solution.

What is the most common challenge in a factory modernization project?

The primary challenge is often logistical integration. This involves coordinating the removal of old equipment, the delivery and installation of new machines, and connecting everything to the existing building infrastructure—all while minimizing production downtime. This requires precise project management and experienced engineering support.