Websol state of the art manufacturing facility include 1.8 GW mono PERC solar cells and 550 MW solar modules. Major advance manufacturing equipments from Germany & quality control testing equipments from . Our manufacturing facility spread 3 lakhs sq feet area . Our plant was designed by German based engineering and construction group , their engineering expertise in electrical , ultrapure water , compressed dry air system design , process cooling water ,HVAC system and waste water treatment not only ensure high product quality but also care environment and safe manufacturing operations .
Installed 10 MVA capacity of load with currently operating 2.5 MVA and can be extending to 10 MVA . This supply line is feed from 33KV underground XLPE cable to reduced interruption. 10MVA Transformer is installed for step down from 33/11 KV, and then 11/0.415 KV by 04 nos. of 2.5 MVA Transformers. Installed Power Factor controlling capacitor bank at LT side to maintain PF more than 0.98. Along with the above system , industrial UPS and one 1500KVA DG system are installed to support our entire Critical load from Voltage fluctuation and Interruption. To promote the green energy 110KW Solar Power Plant is installed in the plant.
Utilities infrastructure developed in consultation with Veolia for ultrapure water . Ultrapure water (UPW), as the name suggests, is water that is free of virtually all impurities. Ultrapure water typically begins with a pre-treatment stage, followed by number of advance water treatment technologies like ,degasser , RO and EDI .At present our capacity is 14m3/hour and same will be increased to 30m3/hour . In addition to UPW, the company installed GEX & AEX systems to control the air quality in the clean room .Cell manufacturing required high purities electronic chemicals and gases , to control impurities and operator safety , advance bulk chemical and gas delivery system are installed with suitable filters and sensors.
Controlled environment is critical parameter in manufacturing of solar cells and module manufacturing. The company has installed three 600TR York international Chillers , four Paharpur cooling towers , number of HVAC systems, four 500cfm Altas Copco compressures for continuous supply of process cooling water and high purity and low moisture compressed air , maintain temperature and humidity of clean room. Installed systems are environmental friendly and energy efficient .PV cell manufacturing machines are based on pneumatic equipment and systems, contamination of compressed air can disrupt processes, leading to costly maintenance , PDP instrument has been installed to auto drain excess water from air receiver.
Advance ETP plant treats process effluent containing acidic and fluoride impurities and contamination generated in the exhaust air. This plant was designed by Veolia inline with regulatory standards. Our ETP team monitors all critical parameters round the clock to protect the environment, complies with regulatory requirements and improve worker health and safety.
Manufacturing of solar PV cell and Module is a complex process and require a range of raw materials like mono-crystalline Silicon, paste, high-purity chemicals, glass, and high-performance polymeric material like EVA and back sheet.
Solar Modules are subjected to several performance tests in the lab to validate product performance. PV modules have got various applications for electricity generation in remote, rural, and even in urban areas. They have applications in different sectors ranging from agriculture to household to industry. The PV modules can be integrated into buildings, serve dual purposes, the outer layer of a structure, and generate electricity for on-site use or export to the grid.
In view of regular technology upgradation in solar cells and modules, check product performance in different environmental conditions and the impact of aging. The company installed 110 KW in-house PV Power plant in 2017 and planning increase to 500 KW, it helps to check field performance of PV module, generate green energy and reduce carbon footprint. Data generated from field performance studies, help us to improve products in line with customer requirements and also help to know raw materials suitability.
Our rich experience in solar cell manufacturing and adoption of current technologies help us to minimize the manufacturing cost and increase efficiency in line with global standards.Our online process control and International certification ensure zero defects in Solar Modules , at Websol , every stage of production from vendor approval of raw materials to manufacturing and post-production is closely monitored product specifications , environment impact and risk assessment.
Each of the manufacturing and quality processes is mapped and recorded as per ISO 9001, ISO 14001 and ISO 45001 standards. These reports are regularly audited at regular intervals by a team of qualified internal auditors. We are continuously upgrade our system inline with regulatory requirements and are committed for the best manufacturing practice.
The ISO and Safety team ensures the development and implementation of SOPs, documentation control and regular internal and External audit as per calendar.