TurnKey Production Lines for Manufacture of PV Modules

Teknisolar Robostak™  lamination lines are installed in high-quality turnkey lines by system integrators who also offer local post-installation services.

Established solar panel manufacturers may need a new line for production expansion, for developing a new solar module product, or a startup company may need to invest in a first line with the intent of increasing production in future. Each piece of equipment shall be chosen according to the customer’s production goals and the technologies that the customer wants to include in their production.

Choosing Teknisolar laminators for your solar module manufacturing facility will put your company at an advantage due to lower running costs and fewer laminators required to meet your required production capacity.

30 solar panels per hour is equivalent to approximately 75 – 110 MW, according to the type of solar panel in production. The level of automation can be increased or decreased according to customer’s requirements.

60 solar panels per hour is equivalent to approximately 170 – 220 MW, according to the type of solar panel in production. The level of automation can be increased or decreased according to customer’s requirements, although front-end processes may need to be fully automatic in order to guarantee the speed of the line.

90 solar panels per hour is equivalent to approximately 250 – 320 MW, depending on the type of solar panel in production. The level of automation can be increased or decreased according to customer’s requirements, although some processes must absolutely be automatic in order to ensure the speed of the line.

120 solar panels per hour is equivalent to approximately 340 – 425 MW, according to the type of solar panels in production. The level of automation can be increased or decreased according to customer’s requirements, although front-end processes must absolutely be fully automatic in order to ensure the speed of the line.

For more information about our laminators, please fill out the contact form, including specific information about your company's solar panel type and size, and we will get back to you within a few days time.


Understanding what goes into a production line

1. Pre stringing

The first process step is the preparation and cleaning of the glass plate. This can be done automatically with pick and place systems, robots and glass washing machine or dry brush cleaner. The first sheet of encapsulant is also applied in this step.

2. Stringing

A high quality stringer is fundamental for any line, and is one of the key factors in production capacity calculations. It is important to choose a stringer made by a reputable market leader. The stringing is a fully automated process. The operator fills trays with solar cells which are fed automatically into the machine and the stringer applies the busbars. Next, the strings are placed accurately on the prepared glass sheet by a robot. Advanced vision and sensor systems ensure proper creation of the cell matrix.

3. Interconnection, inspection & repair

This part of the process is also called “busbar soldering”, where the strings are connected electrically to form a series. This is typically a semi-automatic step, but for high-capacity lines, it is preferable to use a reputable fully-automatic busbar soldering machine.

Inspection with an electroluminescence test should be done at this step, to make sure that none of the cells are damaged and that the electrical connections have been properly soldered. Repairs can be carried out in the next station if necessary.

4. Foil and backsheet placement

Cutting and placement of encapsulant foil (EVA or POE or other) and backsheet material (or alternatively, placement of second glass sheet) should be fully automatic in a high-capacity line.

5. Lamination

Read more about our laminator here.
The Robostak laminator ensures even heating throughout the module, complete removal of air from between the layers using and innovative deep vacuum system, even pressure across the module with no edge pinch, and incredibly high speed, due to the process parameters and machine functions, and also to the multi-stage curing process. This means that a laminator that holds just one solar panel per load can process up to 32 panels per hour. Increasing the number of solar panels per load (up to 4) will multiply the production capacity accordingly. This laminator is designed to work perfectly in short cycle times with both glass-glass and glass-backsheet panels. In addition, this increased production capacity means that the required space for equal capacity is less than competitor laminators.

6. Back end

The back end contains the finishing steps in the solar panel production. All of these steps can be manual, semi-automatic, or fully-automatic, according to the customer’s requirements and budget:

  • Visual inspection
  • Trimming operation to remove excess backsheet (not required for glass-glass modules processed in the Robostak™ laminator)
  • Application of silicone or tape to fix the aluminium frame to the module
  • Pressing the frame around the module
  • Gluing and soldering the electrical junction box
  • Sun simulation/flashing: A light source simulates sun light allowing the power of the panel to be measured
  • PE/grounding test: this test verifies if the 4 frame parts are electrically connected to ensure proper grounding at installation.
  • HV/High Voltage test: verifies that there is no electricity flowing from the network of cells to the frame of the panel, minimising the risk to the installer or user.
  • 2nd Electroluminescence (EL) test: At this stage, it is important to check the quality of the panel and this data is stored for technical/commercial purposes.
  • Labelling, sorting and packing

Calculations are based on using high quality fast-cure EVA and standard backsheet. With special encapsulant materials such as various types of POE, TPO or special backsheet material, or other types of cells like heterojunction, CIGS, etc., the calculations will vary slightly. Lamination cycle time will be the key factor in variation of these calculations; therefore these materials will require a trial session on the Teknisolar laminator in order to accurately size the line according to the customer’s production requirements.