An investor might assume that a solar panel is a universally standard product. Yet, a module engineered for the dry heat of Arizona would face significant performance challenges in the tropical humidity of Southeast Asia. This distinction is not a minor detail; it is fundamental to the long-term success and bankability of a solar manufacturing venture.
This article uses Vietnam as a case study to explore the critical impact of high humidity and sustained heat on solar module longevity. It also outlines how a specialized production approach, like the J.v.G. DESERT+ technology package, addresses these environmental challenges right from the factory design stage. For entrepreneurs entering the solar industry, understanding these factors is essential for producing reliable, high-performance modules that stand the test of time.
The Hidden Challenge: Why Tropical Climates Test Solar Modules to Their Limits
At first glance, regions with high solar irradiation seem ideal for solar energy. However, the combination of intense sunlight, high ambient temperatures, and persistent humidity creates one of the most demanding environments for photovoltaic (PV) technology. This ‘damp heat’ environment accelerates the aging process of materials far more rapidly than dry heat alone.
In a standard solar module, several key components are vulnerable to moisture ingress. Over a 25-year lifespan, even microscopic amounts of water vapor penetrating the module’s layers can lead to significant performance degradation and eventual failure.
A climate like Ho Chi Minh Cityโs presents a relentless challenge. With average humidity levels consistently above 75% and temperatures frequently exceeding 30ยฐC, the environmental stress on a solar installation is constant.
This sustained exposure to damp heat creates a perfect storm for chemical and physical degradation within the module, leading to specific, predictable points of failure.
Common Points of Failure in Standard Solar Modules
When a standard solar panel production line is established without considering these specific environmental stressors, the resulting modules often have inherent vulnerabilities. Over time, these weaknesses manifest in costly ways.
Encapsulant Degradation (Hydrolysis)
The most common encapsulant material, Ethylene Vinyl Acetate (EVA), is susceptible to a process called hydrolysis when exposed to prolonged moisture and heat. Water molecules slowly break down the polymer chains, leading to the formation of acetic acid. This acid can then corrode the solar cell’s metallic contacts and busbars, causing a steady decline in power output. A visible symptom of this degradation is a ‘browning’ or ‘yellowing’ of the encapsulant.
Ready to make big Profits?
The solar Industry is Booming
WE HELP NEWCOMERS to the solar industry start their own solar module production line. Customers can make BIG PROFITS by selling modules and finding investors, without wasting money and time on things they don't need!
Backsheet Permeability and Delamination
A module’s backsheet is its primary defense against the elements from the rear. Standard backsheets, often made from polymers like PVF or PET, have a measurable Water Vapor Transmission Rate (WVTR). In high-humidity environments, this allows for a slow but steady ingress of moisture. This can cause the layers of the module to delaminate, or separate, compromising its structural integrity and creating pathways for further moisture damage.
Corrosion and Potential-Induced Degradation (PID)
Once moisture gets inside the module, it can cause corrosion on the solder bonds, junction box connections, and ribbon interconnectors. The presence of moisture can also create leakage currents between the solar cells and the module frame, a phenomenon known as Potential-Induced Degradation (PID). This can lead to a drastic and often irreversible loss of power, particularly in large-scale solar farms.
A Specialized Solution: The DESERT+ Technology Approach
To build modules that can reliably perform for over 25 years in such climates, the manufacturing process itself must be engineered to combat humidity and heat. The DESERT+ technology package was developed based on experience from J.v.G. turnkey projects in demanding regions. Itโs not a single machine but a holistic approach that integrates specific materials, processes, and quality control measures into a turnkey solar manufacturing line.
The core principle is to create a hermetically sealed, highly durable module from the inside out.
This is achieved by focusing on three critical areas of the solar module manufacturing process:
- Advanced Encapsulation Materials
Instead of standard EVA, the DESERT+ process uses Polyolefin Elastomer (POE) as the primary encapsulant. POE has near-zero water permeability and is highly resistant to hydrolysis. It does not produce acetic acid, eliminating a primary cause of internal corrosion and significantly extending the module’s effective lifespan.
- Impermeable Backsheets and Glass-Glass Design
The standard polymer backsheet is replaced with either a highly impermeable composite backsheet or, for maximum protection, a second layer of glass (a ‘glass-glass’ module). This design effectively creates a near-perfect barrier against moisture from both sides, dramatically reducing the WVTR and preventing delamination.
- Fortified Sealing and Component Protection
Every potential point of ingress is reinforced. This includes using specialized edge sealing materials to protect the laminate perimeter, as well as employing junction boxes with higher Ingress Protection (IP) ratings (e.g., IP68) and potted connections to ensure all electrical components are shielded from moisture.
By integrating these material and process upgrades, the resulting solar module is fundamentally more resilient and better suited for decades of operation in challenging climates.
The Business Impact: Bankability and Long-Term Value
For a new manufacturer, product quality is directly linked to brand reputation and financial success. Producing modules that fail prematurely leads to warranty claims, loss of customer trust, and ultimately, business failure.
Conversely, manufacturing modules engineered for durability provides a powerful competitive advantage:
-
Bankability: Solar projects are long-term investments, and financiers conduct rigorous due diligence on the equipment used. Modules with certified resistance to damp heat, PID, and other climate-related stressors are considered ‘bankable,’ making it easier for your customers to secure project financing.
-
Lower Degradation Rates: While all modules experience some power loss over time, those built with climate-resilient technology degrade at a much slower rate. This translates to higher energy yield and better financial returns for the asset owner over the project’s lifetime.
-
Reduced Warranty Risk: By addressing the root causes of failure during manufacturing, the risk of widespread warranty claims is substantially reduced. This protects the manufacturer’s bottom line and builds a reputation for reliability.
Incorporating these considerations into a solar panel manufacturing business plan from the beginning is a strategic decision that pays long-term dividends.
Frequently Asked Questions
What is the main difference between EVA and POE encapsulants?
EVA (Ethylene Vinyl Acetate) is a widely used and cost-effective encapsulant, but it is susceptible to degradation from moisture and heat (hydrolysis), which can release corrosive acetic acid. POE (Polyolefin Elastomer) is a more advanced polymer with superior resistance to moisture, higher electrical insulation properties, and no acid by-products, making it ideal for high-longevity and high-humidity applications.
Is the DESERT+ technology only relevant for tropical countries like Vietnam?
While the technology was engineered for the most extreme damp-heat conditions, its benefits are universal. Modules built with these principles offer enhanced durability and longevity in any climate. For manufacturers aiming to export to diverse global markets, building to a higher standard of durability provides a significant quality advantage.
How does this approach affect the initial investment in a production line?
The initial capital expenditure for a production line incorporating DESERT+ principles may be moderately higher due to the need for machinery compatible with POE and potentially glass-glass configurations. However, this is an investment in product quality and brand reputation. The long-term financial benefits, including higher product margins, lower warranty risk, and enhanced bankability, typically provide a strong return on the initial investment.
Building a Resilient Manufacturing Operation
The decision to enter the solar module manufacturing industry requires careful planning, and a one-size-fits-all approach is rarely successful. As Vietnam’s case demonstrates, local climate conditions are not a secondary consideration but a primary driver of technical design and material selection.
By understanding the specific failure modes caused by humidity and heat and designing a production line capable of mitigating them, a new manufacturer can produce a superior product. This commitment to quality is the foundation for building a trusted brand, securing project financing, and achieving long-term commercial success in the competitive global solar market.
