300MW Photovoltaic Module Encapsulation Production Line

The 300MW photovoltaic module encapsulation production line is a highly automated integrated system with an annual production capacity of 300 megawatts (MW) of standard photovoltaic modules. It precisely controls and encapsulates solar cells, glass, EVA encapsulant film, backsheets, and other materials through a series of core processes. These include automated soldering (or conductive adhesive bonding), precise layup, vacuum lamination and curing, high-precision automated framing, junction box installation and curing, cleaning, electrical performance testing (such as EL testing), and final packaging. This achieves the efficient, stable, and reliable encapsulation of individual cells into finished photovoltaic modules that meet international standards, boasting high power generation efficiency, excellent weather resistance, and long-term reliability.

Product Features

• Large-Scale, Efficient Production: Annual capacity of 300MW (approximately one million modules), enabling large-scale operation that significantly improves equipment utilization and labor productivity, drastically reducing the cost per watt, resulting in strong economic viability.

• Highly Automated & Intelligent: Core processes (string soldering, layup, lamination, framing, testing) utilize advanced automated equipment and intelligent control systems, greatly enhancing production efficiency and product consistency while reducing reliance on labor and human error.

• Advanced Technology & Strong Compatibility: Employs mainstream mature processes (e.g., multi-busbar/advanced soldering) and features flexible design to be compatible with producing modules of different silicon wafer sizes, layouts, and types (PERC/TOPCon/glass-glass), adapting to diverse market demands.

• Strict Quality Control Throughout: Integrates various online automatic inspection equipment (EL, AI visual inspection, IV testing, etc.) and stringent quality control procedures to monitor key quality points in real-time, ensuring high module yield, high reliability, and excellent performance.

Product Applications

• 1. Construction of Large-Scale Ground-Mounted PV Power Plants

  • This is the core application area for the 300MW encapsulation line. Its large-scale production capability efficiently supplies the massive quantities of standardized PV modules required for large ground-mounted centralized PV power plants, often ranging from tens to hundreds of megawatts. These modules are installed directly in open areas like wastelands, deserts, or hillsides, converting solar energy into electricity fed into the main grid.

• 2. Distributed PV Generation Systems (Commercial, Industrial & Residential)

  • The production line is equally suitable for manufacturing modules meeting distributed PV needs. Products can be widely applied to commercial and industrial factory rooftops, public building rooftops, and residential rooftops. The 300MW capacity allows flexible response to orders of varying sizes for distributed projects, helping commercial/industrial users save on electricity costs and providing households with clean power under the principle of "self-consumption with surplus fed into the grid."

• 3. Commercial/Industrial Parks & Building-Integrated Applications

  • The line can produce modules suitable for captive power plants within commercial/industrial parks and Building-Integrated Photovoltaic (BIPV) projects. These applications require not only power generation efficiency but also focus on module aesthetics, dimensions, and compatibility with building structures. The 300MW capacity supports batch production of customized or specific specification products to meet corporate green energy needs and architectural requirements.

• 4. Agrivoltaics, Aquavoltaics, and Other Hybrid Projects

  • This scale of production line can supply components for "PV+" hybrid application projects, such as agrivoltaics (cropping under PV panels) and aquavoltaics (PV panels mounted over water bodies). Such projects require modules with good environmental adaptability (e.g., resistance to humidity, heat, corrosion) and compatibility with specific mounting structures. The 300MW capacity can support the large-scale module supply needed for these comprehensive projects utilizing combined land/water resources.

Key Considerations

• Precise Control of Process Parameters
  Strictly monitor lamination temperature, time, vacuum level, and curing conditions to avoid under-crosslinking or over-curing of EVA/POE encapsulant films, ensuring module yield and a service life exceeding 25 years.

• Zero Tolerance for Breakage & Micro-cracks
  Implement automated handling throughout with soft grippers and visual positioning. Incorporate online EL inspection at soldering/lamination stages to detect and reject broken cells in real-time, preventing micro-cracked components from entering the market.

• Raw Material Compatibility Management
  Dynamically adjust encapsulation plans based on production orders (e.g., N-type TOPCon/HJT or PERC cells), matching different cell thicknesses (e.g., 130μm ultra-thin wafers) and ribbon types (SMBB/low-temperature ribbon) to avoid material failure.

• Stringent Environmental Control Requirements
  Maintain cleanroom standards at Class 10,000 (≥0.5μm particles ≤352,000 particles/m³), humidity <50% to prevent cell oxidation, temperature at 23±2°C to ensure encapsulant adhesion performance. Environmental compliance rate must exceed 99% annually.

• Intelligent Equipment Coordination & Maintenance
  Establish data connectivity from stringer → layup station → laminator, achieving Overall Equipment Effectiveness (OEE) >85%. Implement precise predictive maintenance for key components (laminator heating plates, stringer electrodes) with replacement cycle accuracy within ±8 hours.