Solar Encapsulation Interlayer Film Manufacturing Plant (EVA / POE / EPE)

Capacity: ~1 GW Equivalent (8.5–10 Million m² per annum)

1. Executive Summary

This Detailed Project Report (DPR) covers the establishment of a state-of-the-art Solar Encapsulation Interlayer Film Manufacturing Plant producing EVA, POE, and EPE films used in crystalline silicon solar PV modules.

The proposed facility is designed around a GWELL/GW-type high-end extrusion line with advanced melt pumping, precision T-die, five-roll calendering, X-ray thickness measurement, and fully automated winding. The plant is sized to support ~1 GW of solar module production per annum, equivalent to 8.5–10 million m² of encapsulation film.

The project targets:

• Import substitution
• Supply to Tier-1 solar module manufacturers
• Long-term compatibility with TOPCon / HJT / N-type technologies

2. Project Objectives

• Manufacture high-quality EVA / POE / EPE solar encapsulation films
• Achieve tight thickness tolerance (±2.5%) and optical consistency
• Meet IEC / UL / TUV solar module standards
• Enable future expansion to POE-rich & co-extruded structures
• Support domestic and export markets

3. Product Description

3.1 Product Types

3.2 Key Specifications

• Width: up to 2600–3000 mm
• Thickness range: 0.4 – 1.0 mm
• Density reference: ~450 g/m² @ 0.65 mm
• Transparency: ≥91%
• Gel content (EVA): ≥80% (after curing)

4. Plant Capacity & Throughput

4.1 Line Output

• Extruder output: 700–800 kg/hour
• Operating speed:
• EVA: 8–14 m/min @ 2600 mm
• POE/EPE: 6–10 m/min @ 2600 mm

4.2 Annual Production

Assuming:

• 330 operating days/year
• 22 hours/day
• Average film grammage: 450 g/m²

5. Manufacturing Process Flow

1. Raw Material Handling (EVA / POE Pellets)
2. Precision Mixing (Conical Mixer)
3. Extrusion (GWS180/35)
4. Screen Filtration & Melt Pumping
5. Multi-layer Distribution (A/B/A optional)
6. T-Die Casting
7. Five-Roll Calendering & Embossing
8. Cooling & Stabilization
9. Online Thickness Measurement (X-ray)
10. Edge Trimming & Slitting
11. Electrostatic Elimination
12. Servo-Controlled Haul-off
13. Automatic Center Winding
14. Scrap Recycling via GWS80 Extruders

6. Major Equipment Summary

6.1 Extrusion & Melt System

• GWS180/35 Single Screw Extruders (2 Nos.)
• Plate Type Hydraulic Screen Changers
• JC-Times Melt Pumps with Water Cooling
• Closed-loop pressure control

6.2 Forming & Calendering

• Five-Roller Casting Calender (3000 mm)
• Silicone + Pattern + Cooling Roller System
• Sub-zero rubber roll cooling

6.3 Automation & Quality Control

• X-ray Thickness Gauge (with or without feedback)
• Automatic T-die lip control
• PLC–Siemens based electrical control

6.4 Winding & Finishing

• Automatic friction center winders (2 Nos.)
• Low-tension trimming & slitting system
• Electrostatic eliminators

7. Utilities Requirement

6A. Plant Layout & Area Requirement

6A.1 Main Production Line Footprint

Based strictly on the supplied installation dimensions for the complete EVA/POE/EPE extrusion line:

• Length: 25 meters
• Width: 6 meters
• Clear height required: 8 meters

Net machine footprint area:
 25 m × 6 m = 150 m²

Enclosed volume (for HVAC / fire design):
 25 × 6 × 8 = 1,200 m³

This height is mandatory to accommodate:

• T‑die head & calender stack
• Overhead cable trays
• Roller quick‑release mechanism
• Crane clearance

6A.2 Mandatory Working & Safety Clearances

For safe operation, roll handling, maintenance, and statutory compliance:

Effective operational footprint:

• Length: ~35 m
• Width: ~10 m

 Operational area per line: ≈ 350 m²

6A.3 Ancillary Areas (Same Building)

6A.4 Total Built‑Up Area Requirement (1 Line – 1 GW)

 Total recommended covered area:

 1,500 – 1,750 m²

6A.5 Structural & Civil Recommendations

• Clear internal height: ≥ 9 m (preferred 10 m)
• EOT crane provision: 10–15 MT (die + roller handling)
• Floor load bearing: ≥ 5–6 T/m² under extruder & calender
• Anti‑vibration foundation blocks for extruders

7.1 Electrical Power

• Connected load: ~550–600 kW
• Supply voltage: 415V / 50Hz / 3-phase

7.2 Water

7.3 Compressed Air

• Pressure: ≥7 bar
• Consumption: ~1 m³/hr
• Oil & moisture free

8. Manpower Requirement

Total manpower (3 shifts): 40–45 persons