A line built to be audited.
The Indore plant runs the way our group has run cement, soap and surgical-suture lines for the world's most demanding customers: measured at every step, documented for every serial.
The module line, step by step.
Ten stations from glass to pallet. Three of them exist only to catch what the others might have missed.
Glass loading and lay-up
2.0 mm AR-coated glass is washed, inspected and laid with the first POE sheet by robot, so the encapsulant is positioned identically on every module.
Ultra-high-speed stringing
Cells are cut, aligned and soldered to 16 round-wire busbars on stringers running at several thousand cells per hour with closed-loop placement and temperature control. This is the step that decides cell-to-module loss.
Lay-up and bussing
Strings are placed, cross-connected and the second encapsulant and rear glass are applied. Automated bussing removes the hand-soldering variability common on smaller lines.
Electroluminescence, first pass
Every laminate is EL-imaged before lamination. Micro-cracks, broken fingers and soldering defects are rejected here, when they are still cheap to fix.
Lamination
Vacuum lamination with process recipes tuned for POE and glass-glass laminates; cross-link degree is sampled and logged per shift.
Framing and junction box
Anodised frames are applied with controlled silicone bead volume; IP68 junction boxes are potted and cured with the diodes tested in place.
Curing
Modules rest in a controlled environment so sealants and potting cure before the electrical test, not after shipment.
Flash test and second EL
Every module is measured on a class A+A+A+ sun simulator, front and rear, and EL-imaged again after framing. The flash result is written to the serial and printed on the label.
Packing
Vertical packing with corner protection, pallet-level manifests listing every serial and its Pmax, ready for reconciliation at site.
Quality is a schedule, not a slogan.
Incoming, in-process and outgoing inspection each run to a written plan with sample sizes, limits and named owners.
Incoming
Cells are sampled for efficiency, colour and EL; glass for transmission and edge quality; encapsulant for gel content and adhesion; frames for anodising thickness. Each lot is released or held on record.
In process
Stringer solder-pull tests every shift, lamination gel-content coupons, EL pass rates tracked per stringer head, and statistical process control on flash-tested Pmax distribution.
Reliability lab
Thermal cycling, damp heat, humidity–freeze, PID, mechanical load and hail sequences run on production samples every quarter, mirroring IEC 61215 so type-test results stay representative of what ships.
Storage integration.
BESS containers are assembled, wired and tested in Indore. What ships has already been charged and discharged in full.
Cell grading and module assembly
Incoming cells are capacity- and impedance-graded; modules are built from matched cells so every rack starts life balanced.
Rack build and test
Modules, rack BMS and DC protection are assembled and cycled as a rack before the container is loaded.
Container integration
Thermal management, fire detection and suppression, DC distribution and communications are installed and commissioned in the container.
Factory acceptance test
Full capacity cycles, efficiency measurement, protection and alarm tests, and a witnessed sign-off with the buyer.
Twenty-five lines before this one.
The group runs 25 production lines across cement, soap and personal care, in India and Indonesia. The solar and storage lines were set up by the same people, to the same standard.
Cement plants, 4 MTPA, contract manufacturing for the majors
Soap and personal-care plants: 4 in India, 2 in Sei Mangkei, Indonesia
Production lines under one management system
People across the group's plants and projects
Audit us.
Buyers, lenders' engineers and certification bodies are welcome on the line in Indore. Bring your checklist.