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Lesson 1: The perfect Size of Your Solar Module Production Line

Lesson 1

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How to Find the Right Size for Your Solar Production

At the beginning you have to define the maximum budget for you solar module production line. After defining the budget you can define the maximum size you can get for the amount of money.

Therefor we will now make some examples for some production lines and some sizes with prices.

ATTENTION 1: The prices are only estimations and some figures for you to get an idea about the total costs. Of course there are a lot of variations so the prices can variate a lot...

ATTENTION 2: The prices are for the machines only! It does not include material financing, building and other costs

ATTENTION 3: We will make a complete overview about all the costs of the different sizes including building and financing of the materials in lesson no. 3!

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What Size of the Production Line?

The smallest size that makes sense will be a 5 MW production.

5 MW means, that all the panels you can produce in one year will be a power of total 5 MW (5 million watt = 5.000.000 Watt).

It is a good idea if you want to start in the business and learn about the solar module production.

The biggest size we ever made was 600 MW which is quite a big installation for the beginning.

Below now we will talk about 3 possible sizes for your solar module production line:

Example 1: 5 MW Production Line

5 MW is a very small line with low invest and low risk. It is perfect if you are going to start and you just want to see if it is a good idea for you to start in the solar module production.

Advantages / disadvantages of a 5 MW line:
  • Good for: Making tests, producing special solar modules
  • Learn about solar: Learn how to produce panels, get into the process
  • Low risk: Low invest (about 120.000 Dollar) and therefor low risk to loose money
  • Low profit: With the small size and the small output 

Example 2: 30 MW Production Line

30 MW is a professional line with a reasonable size. This is not a line "only for learning". The invest will depend on the automatization of the line and the quality and will be in a range of about 500.000 Dollar and 2.000.000 Dollar.

Advantages / disadvantages of a 30 MW line:
  • Good for: Starting a real, professional production on a high level
  • Medium risk: Medium invest in machines (about 1.000.000 Dollar) and therefor medium risk
  • Medium profit: Big enough to make a good running profitable business

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Example 3: 100 MW Production Line

With 100 MW you are at the top of the production lines and you will be able to compete even with the very big producers in the world market. The invest in the machines only will be more than 1.000.000 Dollar and can be 8.000.000 Dollars as well. The total amount for the machines will depend on the automatizations (workers or robots) and the quality (Made in China or Made in Germany).

Advantages / disadvantages of a 100 MW line:
  • Good for: Starting a real, professional production on a very high level where you can compete with the world market.
  • High profit: Big enough to produce for big projects and to compete with the world market
  • High risk: High invest in machines (about 3.000.000 Dollar)

Quality of the Solar Modules

With 100 MW you are at the top of the production lines and you will be able to compete even with the very big producers in the world market. The invest in the machines only will be more than 1.000.000 Dollar and can be 8.000.000 Dollars as well. The total amount for the machines will depend on the automatizations (workers or robots) and the quality (Made in China or Made in Germany).

Advantages / disadvantages of a 100 MW line:

With the size of the solar module production line also the quality is changing.


For example if you have a 5 MW line you have to make most of the work manual:

  • Manual soldering of the cells
  • Manual layup of the strings on the glass
  • Manual loading and unloading of laminator
  • And other manual stations


With a 100 MW line it will make sense to make automations in the most critical parts, for example:

  • Fully automated stringer for soldering
  • Automated layup of the strings onto the glass
  • Fully automated laminator with automated loading and unloading


Besides with a 100 MW line you will be able (and it will be profitable) to invest in testing equipment like:

  • EL testing machine
  • String tester
  • Optical cell tester (inside the stringer)
  • And a lot more!


This automatization and test equipment will give you a much higher reliability in the quality.


Together with other scale effects (you will be able to higher a quality manager with a bigger size of the line) the quality of a bigger line in AVERAGE will be better than with a very small line!

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  • L’ Afrique a besoin de l’énergie renouvelable, pour son développement

  • Good morning sir,I have a projects with Exxon Mobil oil and gass for sola energy in the area of borehole water for the workers qouters and the community.can you handle it?Attention Mr P.Thoma

    • Hi, thanks for your question. We are mainly a service and machinery provider for solar module production machines. We are not making projects for small solar installations. So if you plan to produce panels in your country then we are the right partner. If you search for partners to install solar water pumps, then you are not at the right partner here.

  • So far, it look more interesting, it look like good investment, but I still neeeld to put other things into consideration.

    • Take your time! Making solar panels is a big decision that have to be discussed accurately. Just contact us if you need an offer or you have other questions.

  • This is an eye opener. It would be nice to be at the top of the production lines with robots and all. Thanks.

  • Thanks for the lesson, I’m so interested and looking forward to learning more and applying it

  • I would like to start a 30MW production facility in Botswana. The country have great potential for solar esp in agriculture, domestic and tourism sectors

  • Nice idea and thanks for this information

    But what is the electrical power requirement and it’s cost in solar technology to power the factory for the production of 5MW, 30MW, 100MW etc

    This is arising from Nigeria because electricity supply and it’s bill have closed down a lots of companies so we budget for alternative power when considering a factory

    Regards

  • Thank you very much, my dear friend & teacher Mr. Patrick, Thanks to every one of you in J.V.G /PVKNOWHOW clue. In fact I am highly trailed. Having heard about 99,000 Euro for a start. Pls let me take my time to get ready. I will get back to you.

  • I am an Electrical Engineer from Pakistan I would like to install 30MW production line in Hyderabad, Pakistan. How much it will total cost after installation, commissioning and training to our workers.

  • I want to start solar module production line on a small scale ,5MW production line.

  • Good, and my question is what’s about the materials which should use to produce the final solar panels? At least tell us what’s that materials and how much cost abouts?

  • Hi, I want a 5MW Panel string Line. I am Living İn Turkey. Please How Much Money I have to pay for installation. I am Elektrik_Elektronik Engneer.

  • Good information.
    I am a Zimbabwean how would I get connected with investors so that they can help me to construct 30mw Solar module production line .l am very interested in solar systems holding Diploma in electrical engineering

  • Hi it is a very good work you have put in. I am an engineer6 physics graduate and would like to start with the 5MW module so as to aid me grasp all about solar panel production. Thank you

  • Thanks so much , Dear Friend I am trained photovoltaic engineer , I have not enough budget to start 5MW, but I have enough land to start my working in Afghanistan.

    • Land is one step. You have to find an investor for the line. Will be hard, but if you follow the free lessons you can make it.

  • I studied electrical electronics engineering. I am interested in the solar module production line, but the biggest challenge here is the capital for establishment and the power requirements. Because here in Nigeria, it is not a good idea to rely on the national grid in running a factory, a provision must be made for alternative power source. Thanks, I will continue to plan for it.

  • How much would I need to put up a 5MW, 30MW of solar in Nigeria considering the epileptic power supply in my country and I can also distribute it to my people in the community for a certain price.

  • Thank you for this presentation. I would like to know about the unit dimension irea and bild for a 5 MW unit production

  • It’s a good investment but, for staters, huge sums of money can’t be on our accounts.
    The material issue, drives many out though interested in starting up the solar manufacturing plant.

  • I,m Nigeria based business executive, I want to establish solar module production line of 30mw in Lagos Nigeria, pls give more details on cost and other details.

  • This is good. I would like to start with 5mgt the smallest for now. I shall scale up later. I need this so much in Nigeria. Can I get to know if I can get partner or grant to start up

  • I’m environmental engineer, I’m interested to the Solar production Line because I advise to olicy Lakers thé use of renewable energy in ordre to protect thé Environment but also to ne trained for furnishing consultance worlks at a small ans medium level of Line ower
    Thanks

  • It is advise I am a solar installer in Zimbabwe who still need small quantity of my clients like 300-400watts panel size ×2500=1magawatt please help me

  • Thank you for the idea, but I would like to know if there would be manual assistance needed in the 50MW Production.

    • A very insightful and informative lecture and lesson. I love the basics and the idea of starting a manufacturing the solar panels within Africa. The budget determines the risk one willing to take….

  • I’m Batholomew with electrical experience in northern Uganda 🇺🇬 I would like to install solar 100MW for business and also wanted to do business in the products of PVK#
    Interesting lesson so Inspirational #

  • Hi Thomas. I can’t thank you enough for what you are sharing here. I really appreciate your efforts, the scary part is the financing bit but whole project seems to a great idea.

  • Thanks for the information provided. Am really impressed with the idea looking forward to the next lesson

  • Am grateful for your reply. I understand you only deal with manufacturing. So my request can not be taken here, being that mine is a small biz. Thanks anyway.

  • Very insightful. It is very helpful to gain this basic knowledge about the different levels of investment and their benefits. It also helps to decide on the required budget for any desired level.

  • Its a great idea and I pick much interest and really want to leverage on this to provide good opportunities to Africa subregion.

    Thanks for the lesson

  • Thanks for the lesson it’s so helpful and insipiring , it is my hope to be an independent solar manufacturer

  • Thanks for the information, can the panel be produce by you and be exported to my location

  • Hi, thanks for the overview. i am very much interested in solar panel production. More especially a panel that might be affordable to a local consumer.

    The communities which are to be serviced which do not have Electrical power or cannot afford it are the target population.

    I live in Uganda with a population of over 48 million people at least a good percentage of those will appreciate solar that will be a one time cost thus making this a good venture.

    I was reading thru your Financing and sales profile and you mentioned that you may be of some help in getting a business partners or a grant. My country relies on importation of these solar panels and I must say this is some good investment .

    I await your reply.

    Thanks

    • What we can do is, if you have an investor, that we can make the discussions together. But you have to find the investor, we will take care about the rest.

    • I live in phoenix and own lot of residential real estate I can sell the product or install on my own properties

      • Hi and thank you for your comment. We do only make machines, not solar panels 🙂

  • The instructions and information ate comprehensive,
    is the information contained delevery cost to .any part of the world ?
    desire to follow up from the next lesson

  • The 5 MW makes more sense for a starter which is about the range i can get grant from my government to established if I have good business planplan.

  • Israel from Nigeria. Am highly impressed of your lessons and I will like to venture into it. Power (light) is a major problem in Nigeria.
    My worried now is finance

  • Very helpful looking forward to engulfing my self in these technologies of today and future. Suitable for any level of investment but clearly thriving towards sustainable development.

  • Very clear and on point tutorial to give better knowledge and directions of the business. It also helps to plan for the budgets and asses on your investors and risk. Thank you.

  • Thank you it is well articulated.l would like to start one but the only challenge the material and finances.

  • Very informative, now I have an idea and ready to go through other processes to know where I can start project.

  • This is good. I would like to start with 5mgt. I need this so much in Nigeria. Can I get to know if I can get partner or grant to start up.

    • Sorry, we do not make finance. We make technology, machines, know how transfer, ramp up, training, but finance is your part.

  • These is a good lesson, I have the space to start a manufacturing of solar in Namibia, what is the way to go?

  • Very apt and educative for a beginner. Raises my interest for the project as worthwhile

  • Can you provide the details for

    Infrastructure requirements for 30 mwatt unit
    Power consumptions
    Material requirement and suggestion for oman
    Manpower requirements
    Any other ancillary requirements

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