From Quantity to Quality: The Challenge of Ramping up Domestic Module Manufacturing

The quality of Solar Modules is declining. This edition talks about the why and how to tackle this growing concern!

The Indian Solar Industry is making remarkable progress. As of January, India’s Total commissioned solar capacity has reached 100GW with total pipeline capacity being 234.91 GW.

This achievement has been backed by domestic manufacturing of solar modules. With the latter reaching 60GW in production as of 2024.

Due to the expansion of module manufacturing in India, there has been a sudden decline in the quality of the module being manufactured.

This edition covers all about it, from the latest revised order on quality of solar modules to how manufacturers, and all other parties can work to tackle this problem. Let’s get Going!

MNRE Revises Solar Module Quality Control Order, 2025

The Ministry of New and Renewable Energy on 29th January released a notification that revises and supersedes the Solar Photovoltaics, Systems, Devices, and Components Goods (Requirements for Compulsory Registration) Order, 2017.

What is in it?

1. While the 2017 order just focussed on meeting Basic Industry Requirements, the revised order states to also achieve minimum efficiency levels in the products.

• Mono Crystalline & Thin-Film Modules – 18% efficiency

• Poly Crystalline Modules – 17% efficiency

If your products fail to meet these requirements, they won’t be approved.

2. The 2017 order was only applicable to manufacturers and importers. The revised order now also includes:

• Manufacturers

• Importers

• Distributors

• Retailers

• Sellers

• Lessors(Leasing Companies)

However, Exporters are still exempted from this list. This means that if your products are only made for exports, this does not apply.

3. The new order has added an extra layer of oversight. Market checks will be carried out by BIS or an authorized agency, in coordination with MNRE (Ministry of New and Renewable Energy).

4. Licenses issued under the 2017 regulations are still valid. However, Renewals and new certifications will follow the 2025 regulations.

5. Not following these rules may result in penalties under the BIS Act, 2016.

With this revised order, India is raising the bar for solar module quality and efficiency. The revised order bans low-quality imports and substandard local production, forcing manufacturers to meet stricter efficiency standards.

With stricter efficiency standards manufacturers must upgrade technology and production methods. On paper, it makes sense—better efficiency means higher energy output, reduced land use, and longer-lasting solar projects.

But not everyone is ready for this shift. Domestic manufacturers will need to invest more in R&D and advanced production. This could increase costs in the short term. Smaller importers and distributors, who rely on cheaper panels, may face supply chain issues or be pushed out of the market.

This aligns with Make in India and the National Manufacturing Mission, pushing Indian solar firms to compete globally. It drives investment in advanced technology, strengthening India’s solar manufacturing base.

The shift won’t be easy, but it’s necessary. Higher efficiency, better quality, and a stronger industry will help India meet its clean energy and net-zero goals, securing its place as a leader in solar manufacturing.

Why was it necessary, one might wonder?

The answer, however, came late. Let’s understand what was the need for it.

Declining Quality of Indian Solar Modules

Globally, over the past decade, PV module quality has fluctuated. This can be attributed due to shifts in technology, policy and market forces. A report published by Kiwa PI Berlin reveals how innovation and rapid industry growth have created both progress and setbacks in manufacturing quality of solar modules.

In 2016, defect rates were low (0.65%) due to the maturity of polycrystalline silicon modules and well-established production processes. By 2019, improvements in monocrystalline manufacturing reduced defects.

Larger wafers, multi-busbar technology, and bigger modules (2020) caused a new spike in defect rates. The industry struggled to maintain quality while scaling up production. COVID-19 (2020-2021) added disruptions, but by 2021-2022, better automation and intelligent quality control systems (e.g., automated soldering) helped stabilize defect rates.

But this stabilization didn’t land well for India, Laos and the U.S. As for the trio, the defect rate of solar modules remains the highest - exceeding 8%.

But, there are reasons. The major one being the rapid expansion in the manufacturing capacity.

It is famously said, “With great power comes great responsibility.”

It applies to the Indian Solar Module Manufacturing sector. Now, that we are rapidly increasing our manufacturing quality it becomes our responsibility to simultaneously focus on the quality as well. This becomes very important on the grounds that we do not want to remain as importers only.

“Over the long run, as the Indian module production capacity further scales up we will see a convergence—Indian manufacturers will stand shoulder to shoulder with global players on price and no import protection duty will be needed", said Tanya Singhal, founder of SolarArise & Mynzo Carbon.

Circling back to the original point, this rising defect percentage was surely identified and hence there comes the need to push the sector to focus on the quality as well.

The report also highlighted some major defects that are frequently seen while manufacturing Solar PV Modules.

Common Defects Found in Solar PV

Solar PV modules undergo rigorous quality checks to ensure reliability and long-term performance. However, defects still occur due to material issues, process inconsistencies, and technological shifts.

Before diving into the details, the infographic above provides a breakdown of the most common defects found in PV module production. These issues—ranging from cell and frame defects to material contamination—directly impact module reliability, performance, and long-term durability. Now, let’s take a closer look at what these defects mean and why they matter.

Over 22% of defects in PV module production come from cell-related issues. The shift from PERC to TOPCon cell technology has played a major role in this, introducing new metallization challenges.

In fact, 39% of all cell defects are due to metallization problems, affecting conductivity and efficiency. Another major concern is cell cracks, which weaken structural integrity and reduce long-term performance. These issues highlight the importance of refining new technologies before scaling production.

Frames, which provide mechanical strength, account for 17.82% of defects. The most common issue? Frame damage (40%), often due to material quality. While minor frame defects have limited performance impact, assembly-related defects (39%) pose a bigger risk, potentially affecting module stability.

Other defects, such as poor lamination (10.47%) and glass damage (10.06%), further emphasize the need for better process control and material quality checks. Without strict oversight, these issues can lead to moisture ingress, delamination, and mechanical failures over time.

The data makes one thing clear: as PV technology advances, so do manufacturing challenges.

Stronger quality control, better material selection, and improved process monitoring are key to ensuring reliable, long-lasting solar modules. Addressing these defects will boost industry standards, protect investments, and ultimately drive a more sustainable solar future.

How to Conduct a Solar Panel Quality Check During Production?

Ensuring high-quality solar panels is critical for performance, longevity, and customer satisfaction. Poor quality control can lead to microcracks, power loss, safety risks, and increased warranty claims. Here’s how manufacturers can improve quality checks:

1. Inspect Raw Materials Before Production

Quality starts with the materials used in manufacturing. Any defect in silicon wafers, glass panels, encapsulation materials, or backsheets can lead to performance issues later.

• Check wafers for purity, thickness, and microcracks

• Ensure glass panels have high optical clarity and mechanical strength

• Verify encapsulation materials (EVA) for proper adhesion to prevent delamination

• Test backsheets for moisture resistance and UV durability

👉 Solution: Use automated material inspection systems to catch defects before production begins.

2. Use Advanced In-Process Testing

Manufacturers should monitor quality at every stage of production to detect and fix defects early.

• Electroluminescence (EL) Imaging to identify invisible defects like microcracks and shunt issues

• IV Curve Testing to ensure each solar cell meets voltage and current specifications

• Automated Optical Inspection (AOI) to check for color uniformity, cracks, and misalignment

• Lamination Quality Tests to prevent delamination and air bubbles

👉 Solution: Use AI-based real-time monitoring for early defect detection and intervention.

3. Strengthen Final Product Testing

Before shipping, solar panels must pass rigorous testing to ensure durability and reliability.

• Flash Testing (IV) to verify power output and efficiency

• Insulation & High Voltage Tests to prevent short circuits and leakage

• Thermal & Humidity-Freezing Tests to check resistance to temperature fluctuations

• Mechanical Load Testing to ensure panels can withstand wind, snow, and external stress

👉 Solution: Implement automated stress-testing equipment to enhance consistency and accuracy.

4. Simulate Real-World Conditions with Environmental Stress Testing

Solar panels face harsh outdoor environments, so manufacturers must test them under extreme conditions.

• Thermal Cycling Tests (-40°C to +85°C) to detect expansion-related failures

• Salt Mist & Corrosion Testing for panels used in coastal or humid regions

• UV Exposure Tests to prevent color fading and material degradation

👉 Solution: Use accelerated aging tests to predict long-term reliability.

5. Ensure High-Quality Framing & Junction Box Assembly

Structural integrity is just as important as electrical performance.

• Check frame attachments for secure sealing and stability

• Test junction box waterproofing to prevent moisture damage

• Verify cable and connector durability to withstand environmental factors

👉 Solution: Use robotic assembly lines to improve precision and reduce human error.

6. Leverage Advanced Quality Control Technologies

Cutting-edge technology can enhance defect detection and streamline quality control.

• AI & Machine Learning for pattern recognition in production defects

• X-ray Inspection to detect hidden soldering and junction box issues

• Infrared Thermography to identify hot spots and electrical failures

• Data Analytics to track defect trends and prevent recurring issues

👉 Solution: Implement real-time monitoring dashboards to track production quality.

7. Improve Post-Production & Packaging Checks

Even high-quality panels can be damaged during shipping if not packaged correctly.

• Use reinforced packaging to prevent frame dents and glass scratches

• Perform drop tests to simulate handling and shipping conditions

• Train logistics teams on proper stacking and storage

👉 Solution: Conduct random shipment inspections to verify packaging integrity.

8. Foster a Culture of Quality & Continuous Improvement

A quality-first approach must be built into company culture.

• Regular quality audits to identify weak points

• Employee training on best practices and new testing methods

• Feedback loops between manufacturing, R&D, and customer service

• Third-party certifications (IEC, UL, TÜV) for global quality standards

👉 Solution: Implement a Total Quality Management (TQM) system for ongoing process improvements.

Conclusion

The revised Solar Module Quality Control Order, 2025, is a critical step toward strengthening India's solar manufacturing sector. With declining quality of solar modules, the need is more than ever for these regulations.

As the industry expands, quality control must evolve alongside innovation. The rise in common defects highlights the need for rigorous material inspections, advanced in-process testing, and real-world durability simulations.

With the growing focus on Make in India and the National Manufacturing Mission, this new quality framework ensures that India not only scales up production but also competes globally on performance and reliability.

While the transition will be challenging, investing in automation, AI-driven quality control, and continuous process improvements will help manufacturers stay ahead of industry demands.

The future of India’s solar industry is not just about quantity—it’s about quality, sustainability, and long-term excellence.