Que: How important is encapsulant selection in extending module lifespan beyond 25 years?

Ans: Encapsulant selection plays a decisive role in ensuring long-term module reliability. With advanced technologies like TOPCon and increasingly harsh operating environments, conventional encapsulants are often insufficient.

Poor encapsulation can lead to moisture ingress, UV-induced degradation, corrosion, PID, and contamination-related failures, directly impacting energy yield and project bankability.

Advanced materials such as POE, EPE, and anti-acid EVA significantly reduce water vapour transmission and ionic mobility. At RenewSys, our ENT POE and Anti-Acid EVA are engineered to mitigate corrosion risks and extend service life beyond 25 years. We are also targeting 4X–5X reliability validation standards beyond conventional IEC norms to further enhance long-term durability.

Encapsulant selection is therefore a strategic reliability decision, not just a material choice.

Que: What industry challenges led to the development of “CONSERV AUGMENSHEET”?

Ans: With the shift to high-speed module lines, complex interconnections, and thinner encapsulants, traditional manual insulation methods around busbars and junction boxes have become both a productivity bottleneck and a reliability risk. Manual placement introduces variability, contamination risks, and air entrapment – leading to bubble formation and long-term performance concerns.

CONSERV AUGMENSHEET was developed as a reel-form, automation-compatible solution for high-speed lines. Its optimised flow and conformability ensure consistent sealing and effective insulation, reducing defects while improving productivity and manufacturing yield.

Que: How has “CONSERV AUGMENSHEET” been designed for TOPCon, HJT, and bifacial technologies?

Ans: High-efficiency architectures such as TOPCon and HJT are more sensitive to contamination, moisture ingress, and interface-related degradation. HJT cells are particularly vulnerable at the TCO and amorphous silicon layers, while TOPCon modules can face metallisation corrosion at interconnect points. Even minor contamination can accelerate damp-heat degradation.

CONSERV AUGMENSHEET’s reel-form design and engineered flow properties enable consistent, contamination-controlled insulation sealing in high-speed automated lines. This enhances the protection of sensitive cell interfaces and supports reliable performance in advanced module architectures.

Que: What are the latest module technologies currently offered by RenewSys, and which are seeing the strongest adoption?

Ans: RenewSys is currently focused on N-type TOPCon technology, representing the next phase of high-efficiency crystalline silicon modules. Compared to conventional PERC, TOPCon offers higher efficiency, improved bifaciality, better temperature coefficients, and lower long-term degradation, translating into stronger lifetime energy yield.

We offer modules based on M10R and G12R cell formats, providing flexibility across utility-scale, C&I, and DCR-compliant projects. M10R is witnessing strong adoption across mainstream and government-driven projects, while G12R supports higher wattage classes optimised for large-scale installations.

At present, TOPCon is seeing the strongest market traction and is expected to remain the mainstream technology for the next 4–5 years, driven by performance advantages and superior lifecycle economics.

Que: How does RenewSys ensure quality consistency across high-volume module production?

Ans: Quality consistency at scale is ensured through a comprehensive, multi-layered control framework.

We implement stringent Incoming Quality Control (IQC), Process Quality Control (PQC), and Outgoing Quality Control (OQC) protocols to validate raw materials, monitor in-line processes, and certify finished modules against defined performance standards.

Our manufacturing operations are governed by scientific and statistical process controls, including structured sampling, control charts, and real-time trend analysis to proactively detect deviations using Artificial Intelligence.

Data-linked process control systems provide full traceability from raw material to finished module, ensuring repeatability and process stability at high volumes. In addition, our in-house, state-of-the-art reliability laboratory conducts extended environmental and accelerated ageing tests to validate long-term durability and degradation behaviour.

This integrated approach ensures consistent quality, long-term reliability, and strong bankability across high-volume production.

Que: How is RenewSys preparing for next-generation module formats and higher power classes?

Ans: RenewSys is aligning its roadmap with next-generation module formats through continuous cell, design, and material innovation. We are scaling N-type TOPCon across multiple cell sizes ranging from M10 to G12R, with module configurations spanning 108 to 156 cells. This enables a comprehensive power range from 420 Wp up to 720 Wp, addressing rooftop, C&I, and utility-scale requirements.

In parallel, our latest cell manufacturing line has commenced operations at our Hyderabad facility, strengthening our capability to serve the Domestic Content Requirement (DCR) market and meet ALMM compliance requirements. This enhances supply chain control while supporting India’s localisation goals.

We are also developing module platforms compatible with emerging architectures such as back-contact technologies and perovskite-integrated structures, ensuring readiness for future efficiency advancements.

Material innovation remains a parallel focus, particularly in advanced encapsulant systems that enhance spectral response through improved light down-conversion and contribute to long-term reliability. This integrated approach positions RenewSys to meet evolving efficiency benchmarks and higher power-class demands.