Manufacturing procedure from Sand to Module.

       1.Silicon

Silicon is the starting point of our solar production cycle. It is extracted from sand which is made up primarily of silicon dioxide. As the second most common element of the earth’s crust, there is an almost endless supply. 

Solar wafer

The main product for solar cells

In the second production step, highly pure silicon is melted into blocks at 1,410 degrees Celsius and it then hardens. These blocks are then formed into square columns. These columns are cut into extremely thin slices, or wafers, using state-of-the-art wire-cutting technology. After cleaning and thorough final testing, the monocrystalline and polycrystalline wafers form the basis for the production of solar cells.

Production

The highly pure silicon is poured into a coated mold made of highly pure quartz material and melted at temperatures of more than 1,400 degrees Celsius. Only a single crystal is pulled from the melted silicon mass during the production of monocrystalline wafers. In the production of polycrystalline wafers, the liquid silicon mass hardens and thousands of small crystallines are formed into a block. The blocks created this way are then cut into square columns in the next step.

Solar cell

The basic element in solar modules

The wafers are further processed to solar cells in the third production step. They form the basic element of the resulting solar modules. The cells already possess all of the technical attributes necessary to generate electricity from sunlight. Positive and negative charge carriers are released in the cells through light radiation causing electrical current (direct current) to flow.

Production

The wafer is first cleaned of all damage caused by cutting and then textured. A p/n junction is created by means of phosphorous diffusion which makes the silicon conductive. In the next step, the phosphorus glass layer produced by diffusion is removed.

An anti-reflection layer is added. This which reduces optical losses and ensures electrical passivation of the surface is added. Then, the contacts are attached to the front and back along with a rear contact.

Finally, every individual solar cell is tested for its optical qualities and the electrical efficiency measured.

Solar modules

Solar cells are merged into larger units – the modules – in module production. They are framed and weather-proofed. The solar energy modules are the final solar products and ready to generate power. Sunlight is converted to electrical energy in the modules. The direct current produced this way is converted to alternating current by the inverter so that it can be fed into the public grid or, if the unconverted electricity remains in the house, it can also be used directly.

Production

The cells are wired as solar modules in a fully automated process. The solar cells are first soldered to cell chains, known as strings, during the wiring process. These strings are then connected to a matrix made of, e.g. 60 cells.

In the next step, this matrix is integrated into a layer sequence made of solar glass and three films that are laminated in a vacuum oven at 160 degrees Celsius to become a single unit that is weather-proof and impermeable to water and air. After the connection sockets have been automatically placed, the modules are put in a stable aluminum frame.

Solar applications

Solar application products are complete systems that the operator of a solar power system can use to generate solar energy and feed into the grid. Regardless of the size of your planned photovoltaic system, we offer the ideal solution for every project.

Recycling

The WEEE (Waste Electrical and Electronic Equipment) directive regulates the proper recycling of waste electrical and electronic equipment and its financing by producers and distributers in the European Union. This law for the disposal of electronic waste, which in future also defines discarded solar modules as electronic waste, has been revised at the European level. The European Union requires the implementation of WEEE2 in national law by February 2014. At the time of implementation, a free return system for solar modules will be created in all European Union countries. Producers and distributers will then share responsibility for accepting and properly disposing of returned solar modules. Activities to implement WEEE2 began in January 2014 and some countries have already ratified WEEE2 into national law. However, most EU countries will begin implementation of WEEE2 over the course of 2014.