Solar DPR Module Manufacturing

Solar DPR Module Manufacturing

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Solar Mango strongly believes that DPR is not just a protocol document for the banks and other stakeholders to have it in their files.

Developing a DPR that convinces the relevant stakeholders about the viability of the project in a scientific and justifiable manner could make all the difference between Yes and No for the project.

Who is it for?

  • Large Conglomerates/Businesses looking to diversify into module & cell Manufacturing
  • Entrepreneurs/startups keen on venturing into module manufacturing business
  • Small and medium businesses interested in diversifying into solar module manufacturing
  • Solar businesses – EPCs, developers, system integrators, component manufacturers, service providers – keen on vertical integration into a module manufacturer

What is the Benefit?

This DPR, in addition to providing detailed inputs on the business model, technology used, land and location details and financials, also includes sections on risks and risk mitigation that clearly spell out areas of uncertainties, and also how the adverse effects of each uncertainty can be mitigated.

Give special care to this section of Risks and Risk Mitigation, because this is how you clearly prove to your board or to your external financial investor that your professional team knows what exactly it is doing. Banks and financial institutions do take some risks, as long as they understand the nature of risks involved, and where possible, having a metric to quantify those risks.

Why Solar Mango?

Solar Mango is one of the most respected brands in the Indian solar sector. Our expertise in the technical, market and commercial aspects of solar energy has benefitted over 1500 stakeholders – ranging from industries, commercial establishments, small businesses, entrepreneurs, government, educational institutes and more

Through our focused consulting assignments and research reports, and our team of industry specialists, we bring in in-depth expertise in many critical aspects of solar power plant, especially solar PV

Solar Mango’s Contacts in the Indian Solar Sector Being a pioneer in solar power industry research and consulting (we have been serving the Indian solar power market since 2009 when the solar power growth was just beginning) We also own some of the leading online resources for solar energy in India, Solar Mango has one of the most extensive contact networks with solar industry specialists and experts in the field.

Examples of Similar Work Done – Detailed Project Reports

Solar Mango strongly believes that developing a DPR that convinces the relevant stakeholders about the viability of the project in a scientific and justifiable manner could make all the difference between Yes and No from Investors.

As a result of this belief, Solar Mango has prepared several world-class DPRs which have benefited the developers immensely in every possible way.

To name some of our clients who benefited from our due diligence and Detailed Project Reports:

Client Name Details
Sirwar Renewable Energy

DPR for 2 MW SPV plant in Karnataka under Farmer’s scheme

Madhav Group DPR for a 25 MW solar module manufacturing facility
Kohli Ventures Preparation of Project Report and Due diligence on an innovative solar products firm based out of Chennai. This work resulted in the client committing to up to $200 million in the venture.
Jindal Steel Works

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Solar DPR – Table of Contents

1.List of Tables+

Table 1: Cumulative Capacity
Table 2: Yearly DCR Installations
Table 3: Non-DCR Estimate for Ground- Mounted Sector
Table 4: DCR Estimate for Rooftop Sector
Table 5: Non-DCR for Rooftop Sector
Table 6: Solar Capacities in US & Europe
Table 7: Export Potential for Indian Module Makers
Table 8: Operational Capacity
Table 9: Installed Capacity
Table 10: Imports of Solar Cells & Modules by Value
Table 11: Imports of Solar Modules (MW)
Table 12: Total Solar Module Production Capacity Estimates
Table 13: Top 10 Module Manufacturers in India by Installed Capacity
Table 14: Analysis of key Characteristics of kW-size Residential Projects
Table 15: Analysis of Key Characteristics of C&I Projects
Table 16: Analysis of Key Characteristics of Ground-Mounted Solar Projects
Table 17: Analysis of Key Characteristics of End-user Segments (Rooftop Solar)
Table 18: Module Manufacturers in India by Installed Capacity
Table 19: List of Top Ten Module Manufacturers in the World ranked on total shipments (Source: PV Tech)
Table 20: Competition Analysis for the Indian Solar Module Market
Table 21: Product Features
Table 22: Summary of Annual Potential of Solar Power Plant Installation in India
Table 23: Summary Of High Potential States
Table 24: Scope for competitive differentiation
Table 25: Summary of Domestic & Export Sales Potential for a New Entrant
Table 26: Proposed Distribution Channels
Table 27: Customer segments and potential
Table 28: Preferred End-user segments for EPCs of different sizes
Table 29: Developer Decision-making for Different End-user Segments
Table 30: Comparison between different PV technologies
Table 31: Semi-automated versus fully-automated
Table 32: Specifications of a Cell Tester (Sample Data)
Table 33: Specifications of Glass Washer (Sample Data)
Table 34: Specifications of Tabber& Stringer Machine (Sample Data)
Table 35: Specifications of Layup Station (Sample Data)
Table 36: Specifications of Laminator Machine (Sample Data)
Table 37: Specifications for Edge Trimming Station (Sample Data)
Table 38: Specifications of Semi-automatic framer (sample data)
Table 39: Specifications of Automatic Framer (sample data)
Table 40: Specifications of Sun simulator (Sample Data)
Table 41: Specifications of Lighting Table
Table 42: List of Prominent Turnkey PV Module Line Suppliers
Table 43: Location Details
Table 44: Area Requirement
Table 45: Key Timelines and Milestones
Table 46: Preferred Region for Sourcing of Raw Materials
Table 47: Labour Requirements
Table 48: Electricity & Air Source
Table 49: Comparison of CAPEX based on different parameters
Table 50: CAPEX for European Equipment
Table 51: CAPEX for Chinese Equipment
Table 52: Cost of Production for a 500 MW Module Manufacturing Facility
Table 53: Cost of Equipment for a 100 MW Automated facility (European Manufacturer)
Table 54: Proposed investment plan
Table 55: Key Assumptions for financial analysis
Table 56: Assumptions for expenses
Table 57: Main inputs
Table 58: CAPEX
Table 59: Realistic Scenario – Financial Analysis
Table 60: Optimistic Scenario – Financial Analysis
Table 61: Returns Calculation – Scenario Analysis
Table 62: Summary of Financial Calculations results
Table 63: Cash Flow – Optimistic Scenario
Table 64: Cash Flow-Realistic Scenario
Table 65: Benefits available under M-SIPS
Table 66: Business Risk
Table 67: Project Completion Risks
Table 68: Country and financial risks
Table 69: Policy and regulatory risks
Table 70: List of Solar Frame Manufacturers
Table 71: List of Solar Glass Manufacturers
Table 72: List of Solar Encapsulant Manufacturers
Table 73: List of Junction Box Makers
Table 74: List of Turnkey PV Module Line Suppliers

2.List of Figures+

Figure 1: JSW Group overview
Figure 2: JSW Group performance- A Quick overview
Figure 3: JSW Solar – Organogram
Figure 4: India solar Demand Forecast (MW)
Figure 5: Country-wise Breakdown of Indian solar Exports
Figure 6: Country wise breakdown of Solar Imports 2016
Figure 7: Country-wise breakdown of solar imports 2017
Figure 8: India Solar cell and Module Import- Export Activity-2017
Figure 9: Top States by capacity Installation 2017-2018
Figure 10: Solar PV Value Chain
Figure 11: Solar Module Assembly
Figure 12: Components of a Solar Module
Figure 13: Module Assembly Process
Figure 14: PV Module Production Process
Figure 15: Components of a 200 MW Turnkey production line
Figure 16: Cell Tester and Sorter
Figure 17: Auto Laser Scribing Machine
Figure 18: Glass Washer
Figure 19: Tabber& Stringer
Figure 20: Layup Station
Figure 21: Laminator
Figure 22: Edge Trimming Station
Figure 23: Module Conveyor Belts
Figure 24: Automatic Framer
Figure 25: Sun Simulator
Figure 26: EL Test results
Figure 27: Hipot Tester
Figure 28: Visual Inspection


1.Introduction and Project Description +

  • 1.1 Scope of the Project
  • 1.2 Objective of the project
    • 1.2.1 Objective of the Detailed Project Report

2.Quick Overview of the Project+

3.Market Analysis+

  • 3.1 Market potential
    • 3.1.1 Current and Future Demand
    • 3.1.2 Forecasted Solar Growth in India
    • 3.1.3 Cumulative Capacity – End of 2017: 19100 MW
  • 3.2 Demand Analysis
    • 3.2.1 Demand – Total Market Potential for Indian Module Makers
    • 3.2.2 Estimates for DCR Market Potential
      • DCR Market for Ground-Mounted Solar
      • Non-DCR Market for Ground-Mounted Solar
      • DCR Market for Rooftop Solar
      • Non-DCR Markets for Rooftop Solar
    • 3.2.3 Export Market
      • Emerging Export Markets for Module Makers
      • Export Trends
  • 3.3 Current supply Status
    • 3.3.1 Operational Capacity – Module
    • 3.3.2 Current Domestic manufacturing scenario of solar modules
    • 3.3.3 Trends in imports of modules – now and until 2022
      • Imports
      • Imports of Solar Modules (2017), MW
  • 3.4 Supply
  • 3.5 Market Segments and Sizes
    • 3.5.1 Indian Solar Market Segmentation
      • Size of the Project
        Solar Market Characteristics of C&I Solar Segment – Inferences & Recommendations
        Solar Market Characteristics of Ground-mounted solar projects – Inferences & Recommendations
      • Type of end user
        Solar Market Characteristics by Type of End User – Inferences and Recommendations


4.Competitor Analyses – Module Manufacturing  +

  • 4.1. Major Competitors in Module Manufacturers
    • 4.1.1 Domestic Players
    • 4.1.2 International Players
  • 4.2 Top Ten International Manufacturers
    • 4.2.2 Competition from Chinese & Taiwanese Imports
  • 4.3 Analysis of Top five Domestic solar Module Manufacturers
    • 4.3.1. Vikram Solar
    • 4.3.2 Waaree Energies
    • 4.3.3. Adani Solar (Mundra Solar PV Ltd)
    • 4.3.4. Tata Power Solar
    • 4.3.5 EmmVee Solar
  • 4.4 Brief Details about some of the other Prominent Players
    • Goldi Green Technologies – Low-Medium Capacity Utilization, Mainly Domestic Sales and some Export Sales
    • Navitas Solar – Medium Capacity Utilization, Mainly Domestic Sales
    • Akshaya Solar – Low Capacity Utilization, Only Domestic Sales
  • 4.5 Future Trends for Capacity Addition

5.Marketing Plan+

    • 5.1 Proposed Product Features and Characteristics
      • 5.1.1 Other Recommendations on Features for Solar Modules
    • 5.2 Targeted Market Segments and Sizes
      • 5.2.1 Summary of Market Sizes and Growth for the Solar Modules
    • 5.3 Analysis of Market Segments
      • 5.3.1 Demography
      • 5.3.2 Target Customer Characteristics
      • 5.3.3 Type of end user
    • 5.4 Solar Market Characteristics
    • 5.5 Size of the project
      • Rooftop
      • Residential Rooftop Solar Projects – Inferences and Recommendations
      • Industrial and commercial rooftop solar projects
      • Solar Market Characteristics of C&I Solar Segment – Inferences & Recommendations
    • 5.6 Ground-mounted
      • Solar Market Characteristics of Ground-mounted solar projects – Inferences & Recommendations
    • 5.7 Segment-wise Potential
      • 5.7.1 Ground Mounted Solar
      • 5.7.2 Rooftop Solar
    • 5.8 Region-wise Potential
      • 5.8.1 High Potential States – current and future
        Summary of State-wise Potential
    • 5.9 Industry-wise Potential (for rooftop & captive)
      • 5.9.1 Attractive C&I Sectors
      • 5.9.2 Attractive Institutional Sectors
      • 5.9.3 Indian Solar Market Business Potential – Summary

Key takeaways:

  • 5.10 Competitive differentiation
  • 5.11 Planned mix of export and sales in the domestic market
  • 5.12 Proposed Distribution channels
  • 5.13 Potential customers to be targeted and expected revenues from major customers
  • 5.14 Sales Partnerships

6 .Technology Analyses+

  • 6.1 Modules
    • 6.1.1 Technology Options – Crystalline Silicon vs. Thin Film
    • 6.1.2 Crystalline Module Making
  • 6.2 PV Module Manufacturing Line
    • 6.2.1 Module Line Classification
    • 6.2.2 Machines and Equipment
  • 6.3 Intellectual property status of the technology
  • 6.4 Status of existing patents, copyrights and trademarks
  • 6.5 Details of Technology partnerships
  • 6.6 Technology Partners
  • 6.7 Potential Scope and plan for technology upgrades including back-up R& D
    • 6.7.1 Shift towards higher bus bar design
    • 6.7.2 Newer Cell Technologies – PERC/Back-contact/multi-junction/Half-cut
    • 6.7.3 Bifacial Panels
    • 6.7.4 Flexible Thin Film Panels
    • 6.7.5 Colour and Flexible Series
    • 6.7.6 BIPV Panels
    • 6.7.7 Shift to 1500 V Systems
    • 6.7.8 Printed Solar Panels
    • 6.7.9 Modules with Cell String Optimizers
    • 6.7.10 Infrared Spectrum Solar Panels

7.Location Details+

  • 7.1 Proposed Site for the project
  • 7.2 Location Advantages
  • 7.3 Infrastructural Requirements of the Project
    • 7.3.1 Land Requirement
    • 7.3.2 Factory Infrastructure requirement
    • 7.3.3 Plant construction requirements

8.Project Plan+

    • 8.1 Implementation of the Project
    • 8.2 Key Timeline and Milestones
    • 8.3 Sourcing of Raw Materials
    • 8.4 Labour Requirements
    • 8.5 Details of other Requirements

Electricity & Air Source

  • 8.6 Future Expansion Opportunities

9.Project Financials+

  • 9.1 Cost of setting up the plant
  • 9.2 Total Estimated Cost of the Project
    For European Equipment
    For Chinese Equipment
  • 9.3 Break-up of Operating Costs
  • 9.4 Cost of Equipment
  • 9.5 Investment & Funding
    • 9.5.1 Proposed Investment Plan

10.Financial Analysis+

  • 10.1 Key AssumptionsKey Assumptions for the financial analysis
    • 10.1.1 Assumptions for Expenses
    • 10.2 Financing Details
    • 10.3 Scenario Analysis & Results
    • 10.4 Financial Analysis Results
    • 10.5 Summary of Results
    • 10.6 Cash Flow
      Scenario 1 – Optimistic
      Scenario 2 – Realistic

11.Regulatory Assessment+

  • 11.1 Manufacturing incentives
  • 11.2 Features of M-SIPS Programme
  • 11.3 State-level Incentives
    • 11.3.1 Domestic Content Requirement (DCR)
    • 11.3.2 Export and Import Concessions
    • 11.3.3 Tax Holidays
    • 11.3.4 Key Subsidies Proposed to Help Local Manufacturers (Dec 2017)
  • 11.4 Updates on Anti-dumping duty
  • 11.5 Approvals & Incentives
      • 11.5.1 Environment clearance
      • 11.5.2 Incentives from Government of India
      • 11.5.3 Nil Import Duty on solar equipments

    India issues new specifications for solar power modules

  • 11.6 Module Testing and Certification
  • 11.6.1 Warranties and Certifications

Types of Warranties in Solar Panels
Significance of the types of Warranties
List of Certifications Made Mandatory by the Indian Government
IEC 61215 / EN 61215 IEC 61215 Ed. 2 – Ageing of PV modules
IEC61646 – Thin-Film PV Module
IEC 61730 / EN 61730 – Safety qualifications
IEC 60364-4-41 – Protection against electric shock
IEC 62108 – Concentrator PV modules
IEC 61701 – Salt mist resistance testing on PV modules

12.Risk Analysis and Sustainability Plan +

  • 12.1 Business Risks
  • 12.2 Project Completion Risks
  • 12.3 Country and Financial Risks
  • 12.4 Policy and Regulatory Risks


List of PV Cell Manufacturers – India
List of PV Cell Manufacturers – Global
List of EVA/Back sheet/ Front sheet/ PET/ TPT/TPE/PVB & TCO Manufacturers – Global
List of Major Solar PV Back Sheet Brands Imported in India
List of Manufacturers of Connectors– Global
List of Ribbon Manufacturers – Global
List of Manufacturers of Cables – Global
List of Frame Manufacturers – Global
List of Glass Manufacturers – Global
List of Encapsulant Manufacturers – Global
List of Junction Box Manufacturers – Global
List of Turnkey PV Module Line Suppliers
Sample Quote
Estimation of High Sales Potential Market Segments – C&I sectors for Rooftop and Ground-Mounted Solar