We’ve all seen the downward curve; if solar panel manufacturers manage to lower the cost of their product any further, they might as well be free. That’d be great for installers, but it’s proving to be difficult for panel suppliers to keep up with the demand for system price reductions. During the Solar Power International education session “Advancements in Module Products: How to Make a Choice and Take a Chance,” session moderator Barry Cinnamon of Spice Solar remarked how in order for module manufacturers to stay relevant they somehow have to continue to save installers and solar customers money and provide a unique product.
As module prices have continued to fall, the cost of labor has filled the vacuum. All of the module presenters in this SPI education session recognized this trend and have developed unique products that also reduce labor and manufacturing costs.
Boviet Solar’s president Eric Ma said the next big task for the solar industry will be figuring out how to reduce integration cost, meaning the cost to bring solar to the grid. Boviet Solar knows efficiency and reliability will contribute to lowering this cost, and that’s why the company is focusing on PID-free, PERC modules. The module manufacturer also just announced its new 60-cell monocrystalline modules with built-in racking from Spice Solar. Partnering with a racking manufacturer has allowed Boviet to continue bringing down labor costs along with the cost of its modules.
Nicholas Strevel, senior manager of module technology for First Solar, discussed the thin-film module manufacturer’s new line of product, which was inspired to reduce labor and mounting BOS equipment on utility-scale products. The new Series 5 module (our write-up here) finally brings the CdTe module into the same playing field as traditional cSi modules, both in actual size and standardization. Strevel said First Solar’s smaller Series 4 module has served the company well–growing from 6% to 16% in module efficiency in 10 years using the same equipment and manufacturing lines–but a change was needed to make installation easier on contractors.
A side-by-side installation video comparison of First Solar’s new Series 5 module and a traditional cSi panel.
“A lot of pressure has been put on module manufacturers to lower prices,” Strevel said. “We want to use those methods in all areas. There is a certain amount of labor that can definitely be improved.”
The Series 5 module comes pre-wired and pre-mounted, and installation times are nearly identical to a traditional 72-cell crystalline module. As an installation company itself, First Solar knows how important it is to reduce man-power and effort out in the field.
Finally, new peel-and-stick module manufacturer Lumeta Solar remarked on its own attempts to bring down labor costs in this penny-pinching industry. Timothy Davey, president of the company, said the semi-rigid cSi modules were inspired by concerns of large commercial customers about roof penetrations and mechanical loads, but the modules are also finding popularity on residential installs concerned about weather-proofing and aesthetics. Lumeta’s adhesive method requires no penetrations, and the modules are significantly lighter than traditional glass-framed modules and can be installed more quickly and with fewer crew members. Although the wattage of Lumeta’s modules is lower than traditional glass solar panels, the thin modules do have labor and installation advantages.
It seems as though module manufacturers are taking the reins in bringing the overall system cost of a solar array down as much as possible. After all, they do have great experience in squeezing out pennies of savings already, so they are well-tasked for the charge.