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					</table>In an interview on the sidelines of the Mercom India Renewables Summit 2025, Chetan Amrutkar, Assistant Vice President (Sales) at <a href="https://genxpv.com/" target="_blank" rel="noopener">GenX PV</a>, stated that the government needed to support solar component manufacturing for it to grow in parallel with domestic module manufacturing. He said localization mandates will help the manufacturers of junction boxes, cables, and diodes to grow faster.
Amrutkar also spoke about his competition from imports, his company’s plans for capacity expansion and diversification, and its plans to tap public markets through an initial public offering.
Could you provide an introduction to GenX PV? 
We are a Bengaluru-based company. We manufacture solar PV junction boxes and connectors. We have 20 GW of manufacturing capacity located in Bangalore. We are a fully automated manufacturing facility, and our products are tested thoroughly to ensure they perform optimally for 30 years.
How do you view the manufacturing landscape for Balance of Systems (BoS) components in India? 
Over the last four or five years, solar manufacturing, particularly in module production, has experienced significant growth. The module capacity under the Approved List of Models and Manufacturing has grown to about 100 GW.
There is also a huge scope for BoS component manufacturing.
<iframe loading="lazy" title="Interview with Shri Venkatesh, Founding Partner at SKV Law Offices" src="https://player.vimeo.com/video/1109256479?h=c19e656121&amp;badge=0&amp;autopause=0&amp;player_id=0&amp;app_id=58479" width="100%" height="500" frameborder="0">﻿﻿</iframe>
How does Indian BoS component manufacturing compare with imports? 
We have very strong competition on the price front from imports. However, domestic manufacturing capability under the Make in India initiative is now growing. Essentially, our USP lies in manufacturing high-quality products. We continually engage with our customers to resolve any issues that may arise.
Many of the imported panels and junction boxes fail in the field. Our developers and independent power producers lose a significant amount of generation hours due to such products. We provide them with local support, which they often lack when importing products.
With imported components, even obtaining warranty support on time can be a challenge.
What kind of support are you getting from the government in terms of any incentives or tax breaks?
Currently, we are not receiving any support, which is significantly hindering our growth. We don’t have good profit margins because we have to compete directly with Chinese suppliers.
Solar cells and modules protection from imports with the Approved List of Models and Manufacturers in place. We also need some similar support. That will really help us grow.
Have there been any talks with the government regarding such concessions or incentives for junction boxes and other BoS components? 
We haven&#8217;t had any talks so far because we are currently building our capacities. Once we have enough capacity, we can then approach the government. Solar manufacturing capacity is growing at a very rapid pace. Therefore, the BoS component segment will also need to grow in parallel.
It would also help if the government mandates a certain percentage of local BoS content in tenders.
However, some policy support specific to components is definitely crucial going forward.
What kind of support are you getting from the states? 
We have committed an investment of ₹9 billion in Karnataka. We are hopeful of receiving some kind of support, both from the state and the central government, as we are also creating jobs.
Do you think the industry has the workforce with the skills to perform all these jobs that the component manufacturing space is creating?
When we started GenX PV, component manufacturing was very new. Unlike module manufacturing, there is very limited manpower available. We have been training them at the manufacturing level, as well as in quality control and lab testing. We deploy automated machines, but to operate them effectively, we need to dedicate a significant amount of time and manpower to realize their full potential.
Is the machinery for component manufacturing being produced in India, or do you have to import it?
Automation is very complex. Currently, 90% of the machinery is imported. We are trying to localize the maintenance part.
What are the future plans of your company? 
We plan to expand our capacity from 20 GW to 50 GW in the next two years. Apart from that, we are pursuing backward integration. We will go into cable manufacturing and set up diode assembly lines. We already have some injection molding capacity. We are also planning to diversify into other components, such as aluminum frames.
What type of investment are you considering for the expansion plans?
As I mentioned, we have already committed ₹9 billion to Karnataka, which we will invest over the next two to three years. We will tap the markets with an initial public offering next year. We will probably be the first company in this space to go public.
How do you see the renewable energy industry moving forward in the next five years? 
If we can overcome land constraints and augment the grid infrastructure, we should plan to reach 2,000 GW by 2035. Solar will have a big share because it is one of the easiest ways to expand renewable energy capacity, due to the short project timelines.
We are heavily dependent on one country for technology, so we need to reduce our dependence on it.
Are there any certification standards for BoS components? 
We have to conform to the Bureau of Indian Standards (BIS) and IEC specifications.  BIS will also become mandatory for cables. Going forward, we hope that all components will also be subject to BIS certification, in addition to the PV modules.
(Note: Sections of the interview have been paraphrased for better reading. Check out the video for a full chat)

Lack of Government Support Slowing Growth of BoS Manufacturing: Interview

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					</table>Solar manufacturers can reduce costs and minimize quality defects in cells and modules, and balance of system components by using AI and automation.
A panel discussion titled ‘Technology Innovations Driving Efficiency, Profitability, and Competitiveness in Renewables,’ held on July 24, 2025, at the <a href="https://www.mercomindia.com/event/renewables-summit-2025/register" target="_blank" rel="noopener">Mercom India Renewables Summit</a> 2025, shed light on the technological developments in solar manufacturing including the use of AI.
Industry experts Vikram Kenjale, Vice President (India) at <a href="https://www.gamechangesolar.com/" target="_blank" rel="noopener">GameChange Solar</a>; Chetan Amrutkar, AVP of Sales and Marketing at GenX PV; and Sumit Kumar, Vice President of Operations (Manufacturing) and Technology at <a href="https://www.vikramsolar.com/" target="_blank" rel="noopener">Vikram Solar</a> shared their insights on the topic.
Sishir Garemella, Head of International Business Development at <a href="https://scorecard.pvel.com/" target="_blank" rel="noopener">Kiwa PVEL,</a> moderated the session.
Kenjale of GameChange Solar said that multiple factors contribute to module failures. “We follow IEC standards, and have third-party testing to confirm the compatibility of the modules. We do unbalanced testing of modules, wherein it tests real-time scenarios in the event of a wind/storm.”
He added that for their trackers, they have two sets of purlins; the exterior purlin acts as a shield for the interior array layout, which helps reduce module failures.
Amrutkar of GenX PV said that the advancements in solar module technology are impacting the growth of junction box manufacturing. The company has a 20 GW in-house manufacturing facility, and plans to reach 50 GW in two years.
“For TOPCon, we have 30 ampere junction boxes for G12 and G12, and we have 35 ampere junction boxes because the ICC/IMAX ratings are increasing,” added Amrutkar.
Amrutkar highlighted that automation is reducing errors in the manufacture of junction boxes.
“Earlier, the junction box was manually installed on the module and then soldered.  Now, the entire set of junction boxes is picked automatically and placed at the right locations. Simultaneously, the soldering, potting, and cap fixing happen automatically,” he added.
He said GenX PV had altered the junction box design to enable the movement of the automation arms.
Amrutkar noted that these measures have reduced GenX PV’s production costs and increased the efficiency and reliability of their products.
“We select the right raw materials and diodes for junction boxes. In imported junction boxes PV modules, the selected junction box rating and selected diode ratings are very close to the module rating. We are using much bigger diodes for the forward current. This minimizes overheating of the diode which is one of the key reasons failures in junction boxes,” he said.
He added that GenX PV also tests its components to 3 IEC standards to ensure its components can withstand extreme climatic conditions and performance conditions in the field.
Utilizing AI in Testing
Rayzon’s Barve said that for its 6 GW model manufacturing plant, it has been working on backward integration with aluminium extrusion, and an anodizing unit of 19,800 metric tons per annum.
He revealed that the company also has plans to set up a TOPCon cell line of 3.5 GW in the next financial year.
Barve said that AI is primarily being used for quality testing of solar modules and cells.
“We have a two-three-stage process in model manufacturing where inspection needs to happen on a very regular and stringent basis. Earlier, numerous checks, including EL imaging at the string and module level, and EL imaging post-lamination, were done manually. This has been fully automated. If there is any ambiguity, then an operator comes into the picture to take a final call,” he said.
With the integration of AI in the quality check process, there is now little possibility of human errors.
Barve said AI, coupled with machine learning and machine vision, is being utilized from the start of the manufacturing process through to the assembly lines. “If there is any problem with the cell, the cell gets rejected.”
He said newer manufacturing lines are built with AI integration, making the manufacturing process more accurate.
Upcoming Technology
Vikram Solar’s Kumar added that TOPCon is front frontrunner because its Levelized Cost of Energy (LCOE) is the lowest today.
“Irrespective of other technologies in the market, TOPCon holds around 70% of the market share. Today&#8217;s LCOE is with TOPCon&#8217;s future is definitely with TOPCon with the back contact. TOPCon G12R format will have a longer life than TOPCon with back contact. Perovskite in a tandem form, either with heterojunction or TOPCon, will be the front runner probably three years later from now,” added Kumar.
Talking about solar trackers, Kenjale highlighted how AI is making them weather-smart.
In terrains that require grading, the company inputs topography data from the ground, which is integrated with software to provide a master controller that can give commands to different nodes.
“It sends different commands to individual nodes so that trackers can adjust themselves to avoid the shadow effect on the previous or backward tables. On an annualized basis, it will give 5- 5.5% additional gains,” he said.
Kenjale added that on cloudy days, their solar trackers can be optimized to work without direct sunlight.
“We define a threshold, and when it reaches that threshold, the system maximizes the diffused sunlight that is coming on to the modules. Thereby, you can increase the energy gain. It can also give 6.5% additional gains,” added Kenjale.
Need for Green Skilling
The panelists highlighted the dearth of skilled labor to manufacture build solar components.
Barve said that the entire science and technology related to solar manufacturing needs to come to the academic side as soon as possible.
“We should look at engineering colleges with specialised branches for solar energy. We have also been a bit slow in terms of tapping our existing R&amp;D potential. We see a lot of brain drain due to this issue,” he said.
He said India is completely dependent on imports to establish manufacturing facilities. “With hundreds of gigawatts to be manufactured in India without equipment being made in India, our dependency remains high on imports,” Barve said.

AI-Integrated Manufacturing Will Boost Quality and Reliability of Solar Products

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