Synopsis of Solar Assembly Plant.

Brief Synopsis of a PV Module (Solar Panel) Assembling Plant
1. Brief Project Description and Justification:

Solar PV is manufactured from Crystalline Silicon cell (mono or poly). The cells are manufactured from Silicon Ingot cast from Silicon in a Furnace and then cut in Wafers and sandwiched to PV cells. The process is a High Tech one and needs precision equipment & technology worth Millions of Dollars. Only 40-45 units in the world are in the manufacturing of Basic Cell. Most of the units worldwide are assembling Panels by way of purchasing Cells from the producers. This is preferable because this can be done in smaller, less cost incentive plant closer to end market. The capital cost of transforming the Solar Cell into a laminated solar module is low so the economics of smaller capacity plants can be justified.
2. Technical aspect:
The proposed project is a combination of manual and Semi auto processes. Soldering of the cells and matrix will be manual. Lamination will be most part automated. Most of the remaining steps will be Semi Automated with manual loading, unloading and carrying between stations. All machines, equipment and accessories will be of US, Germany and China origin from reputed suppliers who has long experience of supplying similar equipment to many reputed industries all over the World. The suppliers will install the plant and train the technical personnel of the client.
3. Technology transfer:
Assembly of Solar panel is relatively simple technology and easy for the workers to learn. The engineers and technicians will be trained by the plant supplier both abroad and in - house to ensure highest standard of production and quality.
Few months will be required for getting Standards Certificate for panels from IEC and CE. There are professional organizations that help in getting these certifications.
4. Capacity of Plant :
2.5 MWp (2500 kWp ) of Solar PV Panels / year/ 8 hours @ 15wp- 100wp panel size at 100% capacity utilization. Capacity may be doubled or tripled by introducing 2nd or 3rd shift without increasing any significant capital cost utilizing the optimum capacity of the plant and cost effective utilization of the infrastructure.
5. Fixed Cost of the project
a. Cost of Land: a. Plant and machinery (CNF) b. Clearing charges, etc., c. Local Equipment: d. Air-conditioning installation (4000sft. Prod area only) e. Building 10,000sqft. : f. Electrification, wiring, transformer etc.: g. Installation, Foreign Engineers expenses etc.: h. Office equipment and furniture: i. Initial, start up expenses and certification Total: :
Tk. (Not known) Tk. 3,00, 00,000 Tk. Tk. 7, 00,000 3, 00,000
Tk. 20, 00,000 Tk. Tk. Tk. Tk. Tk. 55, 00,000 10, 00,000 6, 00,000 3, 00,000 40, 00,000
Tk. 4, 34, 00,000
6. Power Required :
Total Connected Load: 80kW Consumption/year: 70KW x 8 hours x 300 days x Tk.6=Tk. 1,150,000/year
7. Costing:
Per Watt cost of manufacturing good quality (most suitable for Bangladesh) of Panel including Packing will be around USD 1.45/ Wp. (Best quality)
8. Sales Price:
The ongoing price of good quality Solar PV Panel in Bangladesh is around USD 1.85/ Wp. (Best quality) Proposed Sale price: USD 1.75/ Wp (Best quality)
9. Gross Profit: @ 100% capacity utilization

2.5 MW x 1000 x 1000 x $ 0.30 ( $ 1.75 - $ 1.45 ) = USD 7,50,000 = TK 5,25,00,000 .00 The capacity and earning can be doubled or tripled only by introducing 2nd. and 3rd. shifts in the same factory.
The capacity and earning can be doubled or tripled by only introducing 2 or 3 shifts in the same factory.
10.
Working Capital requirement :
To be done by the persons who will conduct feasibility study based on cost of Raw material and others provided above and following inventory: 1. 2. Cells are Air shipped every week by Air. Maximum 2 weeks of inventory are required. Other materials to be imported by Sea. Maximum of 1 month of inventory/stock is sufficient considering the proximity of China, Taiwan, and Malaysia etc.
An approximate Amount of Tk. 1, 50, 00,000 may be required as permanent working capital
11.
Market Scenario & Demand Supply position:
A. Govt. has set target to meet 5% of total electricity demand (6000MW)

i.e.300 MW by 2015 and 10% i.e. 900MW by 2020, through Renewable Energy Resources including Solar PV, Wind and Bio-gas out of which around 80% will come from solar only. So, the annual demand of only solar panel will be around 210MW by 2015. Only IDCOL will Install 10,00,000 SHS by 2012. In addition, lot of urban households, Govt. offices, shops, schools, business, Poultry & Dairy, Hospitals, community centers, Commercial complexes, municipalities, agricultural farms. Industries will install their own system to tackle power shortage as well as to comply with Govt. Policy.
As a result, at least, 200MW panels will be required annually by the year 2012. The project can fulfill only 1% of the requirement. Update: 11 November 2010
Applicants for less than 2kw would be asked to install solar panels. Besides, residential consumers demanding above 2kw load would be requested to install solar panels for 3 per cent of their load. Industries and commercial consumers demanding up to 50kw load should install solar panels for supply of 7 per cent electricity, those demanding more than 50kw load would have to install solar panels for 10 per cent electricity and for garment industries it is 5 per cent of the total load.
B. Ms. Electra has set up a plant in Savar with 10MW capacity.

Rahim Afrooz is setting up a solar PV assembling plant. 2/3 Projects having total capacity 10-15MW are in the pipeline. So, at present, there exists a gap of 180MW by 2012 which will be met by import from outside at higher price. Various NGOs who are the major installers are importing panels from China and India at present.

Synopsis of Solar Assembly Plant.

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Synopsis of Solar Assembly Plant.

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Brief Synopsis of a PV Module (Solar Panel) Assembling Plant

1. Brief Project Description and Justification:

5. Fixed Cost of the project

Tk. 4, 34, 00,000

9. Gross Profit: @ 100% capacity utilization

Working Capital requirement :

Market Scenario & Demand Supply position:

A. Govt. has set target to meet 5% of total electricity demand (6000MW)

B. Ms. Electra has set up a plant in Savar with 10MW capacity.

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