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					</table>In an interview on the sidelines of the  <a id="menur4mu" class="fui-Link ___1q1shib f2hkw1w f3rmtva f1ewtqcl fyind8e f1k6fduh f1w7gpdv fk6fouc fjoy568 figsok6 f1s184ao f1mk8lai fnbmjn9 f1o700av f13mvf36 f1cmlufx f9n3di6 f1ids18y f1tx3yz7 f1deo86v f1eh06m1 f1iescvh fhgqx19 f1olyrje f1p93eir f1nev41a f1h8hb77 f1lqvz6u f10aw75t fsle3fq f17ae5zn" title="https://www.mercomindia.com/event/renewables-summit-2025" href="https://www.mercomindia.com/event/renewables-summit-2025" target="_blank" rel="noreferrer noopener" aria-label="Link Mercom India Renewables Summit 2025">Mercom India Renewables Summit 2025</a> held in New Delhi on July 24 and 25, 2025, Sishir Garemella, Head of International Business Development at <a href="https://www.kiwa.com/us/en-us/" target="_blank" rel="noopener">Kiwa PVEL</a>, shared his insights into the evolving landscape of solar module reliability and manufacturing quality.
He stressed that success in global markets depends not only on high-quality products but also on consistent, well-executed manufacturing processes, automation, and workforce training. As India rapidly scales up both module and cell production, Garemella advised manufacturers to prioritize reliability testing and technical talent development.
Please provide an overview of the services Kiva PVEL provides.
Kiva PVEL is a globally recognized reliability testing lab headquartered in California. We operate two labs, one in California and another in China. The Chinese lab primarily tests modules from Chinese manufacturers, while our Napa facility in California handles modules sourced from the rest of the world.
One of our core offerings is the Product Qualification Program, which we revise every few years to reflect the latest trends and challenges in module reliability. This program replicates real-world environmental stresses such as heat, humidity, and UV exposure. It spans a six-month period and includes a range of rigorous test legs to evaluate whether modules can genuinely deliver on their 25 to 30-year warranty promises.
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We have seen TOPCon modules achieve higher efficiencies than Mono PERC, but they also show higher degradation in Indian conditions. Why is that?
Yes, TOPCon is a relatively newer technology, whereas Mono PERC has been around for a while and is more established. In our testing, TOPCon modules have exhibited an issue called UV-induced degradation (UVID).
The industry has not yet pinpointed the exact cause of this degradation. It could stem from the cell itself, the encapsulant, or a combination of factors. In some cases, the degradation appears to reverse when the module is kept in the dark and re-flashed. It is still an open area of investigation. That said, all modules, regardless of technology, undergo the same environmental reliability testing.
How do Indian modules compare with those from Western manufacturers under lab testing?
Indian modules are generally on par with global counterparts in terms of long-term reliability. However, as with any market where manufacturing is relatively new, including India, Laos, Indonesia, or even the U.S., we notice slightly more quality assurance (QA) and quality control issues.
These are not structural failures but are indicative of the early-stage learning curve. As the industry matures and production stabilizes, these issues tend to decline. Overall, Indian manufacturers are holding up well under our reliability standards.
What do Indian module manufacturers need to focus on to compete on the global stage?
Two critical factors define long-term performance. One is the bill of materials (BOM). Choosing the right materials is foundational. The second is the manufacturing process. Even with the same BOM, different manufacturers can get drastically different results based on their operational practices.
One of my colleagues puts it nicely: If you and I bake a cake using the same recipe, we could still end up with completely different cakes. It is not just about the ingredients. It is about how skilled your workforce is, how automated your line is, and how tightly you control process variables. Indian companies that invest in both quality materials and robust manufacturing practices are already doing quite well.
India is scaling up module and cell manufacturing rapidly. How can quality be ensured during this expansion?
I have two key suggestions, one conventional and one slightly unconventional. First is the need for more testing and accountability. As the industry scales, there is more at stake. India is no longer a small-volume market. We are talking about 95-plus GW of module capacity. If something goes wrong with even a single 200 MW project, the financial exposure is significant. That is why developers, financiers, insurers, and downstream players must enforce batch-level reliability testing. Whether the testing happens in India or at our labs in the U.S. or China, the point is to embed this into the procurement and financing process.
Second is a focus on talent development. This is less discussed but critically important. Module manufacturing is process-heavy. It is like running a well-organized assembly line where attention to detail and a trained workforce matter. Cell manufacturing, on the other hand, is quite different. It is more like cooking, where minor changes in the recipe can lead to very different outcomes. A pinch of something added today might not behave the same tomorrow. So we need experienced technical leadership, focused R&amp;D, and long-term investments in skill-building, especially as India begins scaling its cell manufacturing base. In summary, process control, skilled workforce, and technical expertise are just as important as speed and scale.

India Must Enforce Strict Testing as Solar Manufacturing Volumes Surge: 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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