25 MW Solar Module Production Line – Plant Setup & Investment Guide
An Executive Overview of the 25 MW Line
For entrepreneurs ready to scale, regional distributors seeking supply chain independence, or investors targeting a robust, semi-automatic manufacturing solution, the 25 MW solar module production line represents a strategic step forward. It serves as the bridge between a pilot project and a larger, fully automated facility.
This line is engineered for growth. It offers a balanced capital investment (CAPEX) while delivering significantly higher throughput—up to 1,800 cells per hour. This capacity increase directly translates to a more favorable return on investment. The design remains compact, allowing for installation in reasonably sized facilities, yet it is fully scalable to accommodate future expansion.
The specifications outlined below are not estimates; they reflect our standard offers and provide a clear, reliable foundation for your business planning.
Technical Specifications
The 25 MW line is engineered for efficiency and adaptability, capable of handling modern cell and module formats.
- Cells per Hour: 1,800
- Modules per Lamination Cycle: 1
- Typical Capacity: ~20 MW per year (based on standard operational efficiency)
- Maximum Capacity: 25 MW per year
- Maximum Panel Size: 2,400 × 1,400 mm
- Supported Cell Types: M2 to M12
- Busbars: Up to 20 BB
- Automation Level: Semi-automatic layup
- Delivery Time: 6–9 months for a new line
- Standard Payment Terms: 30% down payment, 60% before shipment, 5% upon installation, 5% upon final acceptance
Specification Summary
- Nominal Throughput: 1,800 cells/hour
- Annual Capacity (Max): 25 MW
- Max. Module Dimensions: 2,400 × 1,400 mm
- Supported Cell Sizes: M2 – M12
- Automation Level: Semi-Automatic
- Delivery Lead Time: 6–9 Months
What’s Included: Your Bill of Equipment
A 25 MW production line from J.v.G. is a complete system where each station is designed to work in harmony. The line is inherently modular, allowing for targeted upgrades as your production demands grow. A typical bill of equipment includes:
- High-Speed Stringer (1,800 cph): The heart of the line, soldering cells into strings with high precision and speed.
- Semi-Automated Layup Station: Places the cell strings accurately onto glass and EVA foil, assisted by operators for quality control.
- Manual/Assisted Bussing Station: Here, operators connect the strings into a complete module matrix.
- Laminator: A critical station that bonds the module layers under heat and vacuum, encapsulating the cells for long-term durability. This line uses a one-panel-per-cycle configuration.
- Foil Cutter & Placing Station: Prepares and positions the backsheet and EVA foil layers.
- Trimming Station: Removes excess material from the edges of the module after lamination.
- Semi-Automatic Framing Station: Applies the aluminum frame to the module, providing structural rigidity.
- J-Box Station: Mounts the junction box, which houses the bypass diodes and output cables. This station can be upgraded to a semi-automatic process.
- LED Flasher (Sun Simulator): Tests the finished module’s electrical performance under standard test conditions (STC) to classify its power output.
- Hi-Pot & EL Tester: A combined station that conducts safety (high potential) tests and electroluminescence (EL) imaging to detect microcracks and other hidden cell defects.
Line Layout and Operations
The production process follows a logical, linear flow to maximize efficiency and minimize material handling.
- Stringing: Cells are soldered into strings.
- Layup: Strings are assembled on glass with encapsulants.
- Lamination: The module “sandwich” is cured and bonded.
- Framing & Finishing: The frame and junction box are attached.
- Testing: Final quality control and power classification occur.
- Packing: Modules are prepared for shipment.
Staffing:
A semi-automatic 25 MW line typically requires approximately 20 operators per shift. This configuration significantly improves output per operator compared to a smaller 15 MW line, which boosts overall operational efficiency.
Quality Control:
Critical QC checkpoints are placed after lamination (visual and EL inspection) and at the final testing stage (flasher, Hi-Pot, and final EL), ensuring that every module meets stringent quality standards.
Investment, OPEX, and ROI
While the capital expenditure for a 25 MW line is higher than for an entry-level system, the increased throughput fundamentally improves the return on investment. The ability to produce more modules with a marginal increase in labor costs reduces the cost per watt, strengthening your market position.
The difference between typical output (~20 MW/year) and maximum output (25 MW/year) depends on factors like operational uptime, shift patterns, and supply chain efficiency. Our team helps you model these scenarios accurately. The line’s scalability protects your initial investment, as it can be expanded to meet future demand without a complete replacement.
For a detailed financial projection tailored to your specific market conditions and business goals, we invite you to request a formal offer.
Request a Tailored Offer
Use Cases and Ideal Buyers
This production capacity is an ideal fit for a range of business profiles:
- Growing Startups: Companies that have validated their business model with a pilot line and are ready to scale production for commercial contracts.
- Regional Distributors & Manufacturers: Businesses seeking to reduce reliance on imports, control their supply chain, and serve local markets more effectively.
- Mid-Sized EPCs: Engineering, Procurement, and Construction companies aiming to vertically integrate and secure a stable supply of high-quality modules for their projects.
- Government-Backed Projects: Initiatives focused on local content requirements, job creation, and energy independence that require a substantial and reliable output.
Why Partner with J.v.G. Technology?
Choosing a technology supplier is about more than equipment; it’s about securing a partner for the life of your factory.
Founder-Led, Family-Run Expertise
With over 25 years of hands-on experience, our company is led by its founders. This ensures a direct line of communication and a deep commitment to your success, grounded in proven engineering integrity. When you work with us, you work directly with the Thoma family.
Technology Tailored to Your Needs
We do not believe in one-size-fits-all solutions. Our production lines are modular and scalable, so we can design a system that precisely fits your budget, building, and business goals. Explore our approach to tailored technology.
Built for Demanding Environments
For projects in challenging climates, our specialized DESERT & TROPIC technologies ensure long-term module reliability by protecting against heat, humidity, and dust.
A Proven Roadmap to Success
Your vision is important, and our job is to make it a reality. We guide you through every stage with our proven 6-phase process, from the initial concept to a fully operational and profitable factory.
Ready to discuss your project with the people who will build your line?
Talk to our founders.
Your Upgrade Path: From 25 MW to 50 MW
A 25 MW line is designed with growth in mind. As your market share increases, you can double your capacity to 50 MW with targeted upgrades rather than starting over. This typically involves adding a second stringer and laminator, as well as increasing automation at the layup and bussing stations.
25 MW Line (Initial)
- Laminators: 1
- Stringers: 1 (High-Speed)
- Layup: Semi-Automatic
- Footprint: Compact
50 MW Line (Upgraded)
- Laminators: 2
- Stringers: 2 (High-Speed)
- Layup: Fully Automated (Optional)
- Footprint: Expanded
Learn more about other capacity options:Explore the 15 MW Production LineExplore the 50 MW Production Line
Frequently Asked Questions
What is the required factory footprint for a 25 MW line?A typical 25 MW semi-automatic line requires a building with approximately 2,000 to 2,500 square meters of clear floor space and a ceiling height of at least 5 meters. This footprint accommodates the production line itself, plus space for raw material storage and finished goods.
How many staff are needed per shift?With its semi-automatic configuration, a 25 MW line generally requires around 20 operators per shift to manage production, quality control, and material handling.
What are the main utility requirements?The line requires a stable electrical power supply (specifications provided in the offer), compressed dry air for pneumatic components, and standard facility infrastructure. We provide a detailed utility checklist during the planning phase.
What warranty and training are included?All our equipment comes with a comprehensive warranty. We also provide extensive on-site training for your operators and maintenance staff during installation and commissioning, ensuring a smooth handover and self-sufficient operation.
What does the delivery and acceptance process involve?Delivery is typically 6–9 months after the down payment. The process includes pre-shipment inspection, on-site installation and commissioning by our engineers, and a final acceptance test (FAT) to confirm the line meets all contractually agreed performance criteria.
How does scalability work for a 25 MW line?Scalability is built-in. The most common upgrade path is to a 50 MW capacity by adding a second laminator and stringer to eliminate bottlenecks. Further automation can also be added to the layup and bussing stations to increase throughput and reduce labor dependency.
We are here to help you navigate every step of the process. For a complete equipment list and a preliminary financial model, please request our sample offer.
Download Sample Offer (PDF)
If you are ready to discuss the specifics of your project, we invite you to contact us for a direct consultation.