Building a Self-Reliant Solar Ecosystem: The Cell-to-Module Challenge

To explain, a solar cell is like the engine of a panel. A module is the complete unit that powers homes and industries whereas vertical integration means controlling every step—from raw silicon to the final panel, within one ecosystem.

October 21, 2025. By News Bureau

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Solar Cell Manufacturing

Solar ecosystem

India is on the cusp of a solar revolution. But to truly lead the world, we must become self-reliant—not just in installation, but in the entire solar manufacturing chain.

At Rayzon Solar, we’ve always believed that ‘Atmanirbharta’ in clean energy starts from the ground up. That means not just assembling modules, but making our own cells, frames, glass, and more. This journey towards full integration—right from solar cells to modules—is filled with challenges. But it's a leap India must take.

Here’s a clear look at what this journey involves.

The Dream: Cell-to-Module Vertical Integration

To explain, a solar cell is like the engine of a panel. A module is the complete unit that powers homes and industries whereas vertical integration means controlling every step—from raw silicon to the final panel—within one ecosystem. Therefore, vertical integration is important, as it ensures better quality control, lower cost over time, reduced import dependence and faster innovation.

The Challenges We Face

India Still Imports Core Tech

Even now, much of the high-efficiency solar cell machinery comes from countries like China and Germany. This slows us down and increases costs.

Tech Obsolescence Is Rapid

Today’s solar tech becomes old in just 2–3 years. By the time you set up a factory, newer tech has already arrived. We saw this when PERC cells peaked, but TOPCon and HJT began trending.

High Capex and Long Payback in Solar Cell Manufacturing

Setting up a cell manufacturing line needs a massive investment and ROI takes years as compared to module manufacturing which is less capital-intensive.

Talent Crunch in Solar Cell Manufacturing

Module lines need trained hands but cell lines need trained minds. India lacks experienced process engineers for solar cell R&D and production.

Global Pricing Pressure

Chinese firms have achieved gigantic scale, so their manufacturing costs are very low. They sell at low costs in global markets, making it tough for Indian manufacturers to compete unless we match scale and efficiency.

Real Life Example: A Lesson from Vietnam

Vietnam tried to localise cell and module production. But with weak ecosystem support, they had to keep importing wafers and machines. Result? Cost overruns, Missed timelines Factory closures. That’s exactly what India must avoid.

Rayzon’s Approach to Self-Reliance

We’re not just assembling panels—we’re preparing for the complete chain:

Aluminium Frame Manufacturing: We have started manufacturing solar panel frames in India. This reduces import costs and ensure durability.
Cell Line Planning: We are actively investing in our first cell line. It’s designed with scale, tech flexibility, and efficiency in mind.
Tech Partnerships: Instead of building everything from scratch, we’re exploring collaborations with global tech players for faster ramp-up.
People First: We’re upskilling young engineers across Surat and Gujarat to support our future integrated plant.
Smart Investment, Not Blind Expansion: Rather than rushing, we’re studying market trends, like the growing shift to N-Type cells, before making large-scale commitments.

What India Needs to Do

Speed Up Performance Linked Incentive (PLI) Scheme Execution
Subsidies must reach manufacturers faster
Support R&D at the MSME Level
Not just big giants—smaller innovators need grants and lab access
Invest in Talent Pipeline
Universities should offer solar cell manufacturing as a specialisation
Enforce Fair Import Duties
Stop dumping, but also ensure duties don’t hurt EPC players in the short run

The Way Forward

Building a self-reliant solar future is like building a temple. You can’t start with the rooftop—you need a strong foundation. At Rayzon Solar, we’re laying each brick carefully—from cells to modules, from talent to technology. India doesn’t just need solar power. It requires solar strength. And that strength must come from within.

- Chirag Nakrani, Founder and MD of Rayzon Solar