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An Alternative PV Module Manufacturing ModelEd Hurley
September 6 , 2011
A Solar PV Company providing capital equipment & turn-key production lines for module manufacturing
worldwide.
The Turn-key Solar Factory Company
Spire Corporation (Nasdaq: SPIR)
Alternative Module Manufacturing Model
Converting Laminates into Modules• Low cost way to expand or enter into market• Reduced Financial risks
– Lower CAPEX, start-up costs
• Lower operating cost– Higher yields– Leverage low cost Laminate suppliers
• Accelerated Market Entry– Design ready laminates= faster certification
From Laminate to Module
Post Lamination Assembly = FAST Line• Final Assembly Simulation & Test
– Post Lamination module line
• LEAN manufacturing principles.– Quick and low-cost startup for module assembly.
• Consistent, high quality output.• Easily deployable into any region
– Take advantage of local incentives
Demand Flow Technology Based Design
100% Inspection
Ergonomic Tooling
Balanced Labor Approach
Laminate to Module FAST Line
Important Equipment Considerations
• Equipment similar from line-to-line– Work with high quality PV equipment supplier
• Level of automation affects staffing and price– Semi-auto, automated, fully automated
• Line should be flexible and configurable• Do not focus on cost at expense of metrology
– Metrology is critical to success of line• Need high quality Simulators & EL systems• Database management increasingly becoming more critical
• Framing– Configurable for tape or sealant
• Junction Box– Configurable for different j-Boxes
• Simulation– Performs IV test to IEC/UL standards
• EL– Module inspection, cracks/microcrack
• Packout– Bin and box module
Typical Module Equipment
Selection of Equipment Supplier• Use known reliable equipment• Support services crucial
– Planning– Project management– Installation & ramp-up support– Training
• Ability to develop customized financial models– What is best suited for your application
• Ability to provide Module certification assistance• Help with supply chain
– Especially on high-quality laminates that will work with the line
Payback on Investment
• Must have detailed financial model• Review trade-offs on equipment, materials, process
Module Sale Price ($/W) $1.35
Solar Laminate Cost ($/W) $1.00
Other Costs* ($/W) $0.20
Gross Profit ($/W) $0.15
Less SG&A $0.08
Net Income ($/W) $0.07
ROI < 8 months* Other Costs include (O&M, Labor, Non-Laminate Materials, Overhead, and Depreciation)
Summary• World market is continuing to grow• FAST Lines ideal way to capitalize on market
conditions– minimal capital expense & reduced risk
• FAST line is scalable and flexible for future expansion• Carefully select your PV equipment supplier• Carefully study financial models
