Eastman Solar Panel Manufacturing Plant – Complete Process Explained | BEST Solar Panels For Home
In India, you will find many brands claiming that their solar panels are the best. However, a brand does not become the best just by saying so. The true quality of a brand is proven when it manufactures its own products and maintains strict quality control. That is why today we visited Eastman’s solar panel manufacturing plant to see how high-quality solar panels are produced step by step.
Eastman offers a wide range of solar panels using advanced technology.
● Solar panels available from 40W to 590W with modern TOPCon technology
● 550W DCR solar panels used in government subsidy schemes
● High-quality panels suitable for residential, commercial, and EPC projects
Let us understand the complete manufacturing process as explained by the Quality Head.
● Raw Material & Cell Preparation
The process begins with issuing raw materials as per the daily production plan.
● Solar cells are loaded into the fully automatic tabbing and stringer machine
● Laser cutting and CCD inspection check for cracks or internal defects
● Defective cells are automatically separated
● Cells are cut according to the required panel model (for example, 182mm cells cut into half cells)
Only defect-free cells move forward in the production line.
● String Formation & Soldering
After cutting and inspection:
● Cells are connected in series to form strings
● For a 550W, 144-cell model, 12 cells are joined in one string
● IR lamps are used for precise soldering
● Automatic robots handle placement and movement
Each string undergoes EL (Electroluminescence) testing and visual inspection to detect hidden micro-cracks or defects.
● Glass, EVA & Layering Process
The next stage involves panel layering:
● Front glass is automatically loaded
● EVA (encapsulation material) is cut and placed according to panel size
● Strings are placed on EVA using robotic systems
● Auto bussing connects strings in series and parallel configuration
● Output terminals are prepared for junction box connection
● Automatic taping ensures strings remain stable during lamination
Depending on the model, panels can be:
● Glass-to-Backsheet
● Glass-to-Glass
● Lamination Process
Lamination is one of the most critical steps.
● Fully automatic laminators with top and bottom chambers
● Lamination temperature around 150°C
● Each panel takes approximately 26–27 minutes
● Production capacity around 200 panels per hour
After lamination, extra material is trimmed automatically.
● Quality Inspection & Grading
Quality control is done at multiple stages:
● Visual inspection after lamination
● EL testing for hidden defects
● Panels are graded as A Grade, B Grade, or Rework
● Grading stickers are applied for identification
This ensures that any issue is detected immediately, preventing large-scale defects.
● Framing & Junction Box Installation
After quality approval:
● Aluminum frame is fitted using automated machines
● Junction box is installed and soldered
● Panels are kept for curing for 4 hours at controlled temperature and humidity
● Power Testing (Sun Simulator & IV Testing)
Each panel undergoes performance testing:
● Artificial sunlight of 1000 W/m² is generated
● Standard test condition temperature maintained at 25°C ±2
● Power, current, voltage, and fill factor are measured
For example:
● A 550W panel typically generates 553W to 557W, ensuring positive power tolerance
If any panel underperforms, it is graded separately.
● Safety Testing (Hi-Pot & Leakage Test)
Safety is equally important.
● 4800V DC applied for high-voltage testing
● Leakage current checked
● IR and ground continuity tests performed
● Any failed panel is removed and re-verified
● Final EL & Visual Inspection
Before packing:
● Final EL test
● Final visual inspection
● Grade confirmation (A Grade / B Grade / Rework)
Each panel is tested multiple times during the entire process.
● Packing & Dispatch
● Automatic sorting system separates panels by grade
● 28 to 32 panels packed per pallet
● Ready for dispatch
The production line shown was for 550W DCR solar panels used in government subsidy schemes.
Contact Us :
Email : Engineerbharatyt@gmail.com
Facebook : https://fb.com/engineerbharatyt
Instagram : https://www.instagram.com/erbharatyt/
Solar panels for home,solar panel installation,solar panel system,Solar Panel Manufacturing,solar panel manufacturing process,solar panel manufacturing machine,solar panel manufacturing equipment,solar panel manufacturing business,solar panel production line,solar making machine,solar panel making machine,how solar panels are made,solar panel making process
Leave a Reply