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High Defect Rates in Indian Solar Modules Highlight Quality Challenges

Feb 20, 2025

India, along with Laos and the U.S., has one of the highest solar module defect rates globally, exceeding 8%, according to Kiwa PI Berlin’s 2025 PV Module Manufacturing Quality Report. The rapid expansion of manufacturing capacity has introduced challenges in quality control, workforce training, and operational stability, impacting overall module reliability.

The report identifies key quality concerns in newer solar manufacturing hubs like India, the U.S., Laos, and Malaysia, where production is growing but lacks the maturity and efficiency seen in established ecosystems like Thailand, Cambodia, and China. Factors contributing to high defect rates include insufficient training, poor equipment conditions, material mishandling, and operational inefficiencies.

Major Defects in 2024 Pre-Shipment Inspections:
  • Solar Cell Metallization and Cracking (22%): Defects stem from the transition from PERC to TOPCon cell technology.
  • Frame Assembly Issues (17.82%): Open corner gaps in module frames increase risks of glass breakage and mechanical failures.
  • Foreign Material Contamination (12.1%): Debris during production leads to moisture ingress and mechanical degradation.
  • Poor Lamination (10.47%): Weak lamination can cause delamination, structural instability, and environmental damage.
  • Glass Damage (10.06%): Scratches and cracks compromise mechanical strength and durability.
Recommendations for Improved Quality:
  • Stronger material quality control to prevent defects in solar cells and module frames.
  • Enhanced process monitoring to address defects in lamination, glass handling, and contamination control.
  • Regular maintenance and calibration of manufacturing equipment.
  • Stricter inspection criteria in supply contracts to improve overall manufacturing standards.

With India's growing solar ambitions, maintaining high manufacturing quality will be essential to ensure long-term performance, safety, and reliability in the renewable energy sector.