Celestica Solar Panel Manufacturing Thailand
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1 Solid partners. Flexible solution. Celestica Solar Panel Manufacturing Thailand Lines 1 & MW (240 MW Per Line) 7/2/2017 Celestica Page 1 of 45 June 2017
2 Introduction Celestica is a contract manufacturer that entered the Solar business in 2011 in Toronto Canada, producing solar panels and expanded the business globally into Thailand in Q We have selected Liquidity Services to market (3) fully ramped semi automated Solar production lines that are located in the Laem Chabang Industrial Estate in Thailand, (90 minutes from Bangkok). We are looking at potential buyers who are looking to bring capacity online in a very short time for their production. We are currently exploring 2 options. Option 1 We are looking for clients to operate and run the factory in place. The client will lease the space, purchase the equipment and operate as a independent company. Celestica can provide some technical assistant during the ramp period. We are also open to other proposals based on the clients needs. Option 2 Purchase and move the equipment. The buyer will be purchasing the assets in-place and be responsible for de-installation, packing & crating, transportation and re-installation costs. We can recommend several very qualified full-service vendors. Here is a estimation for the following cost associated with moving each of the production lines. This could be anywhere between $500K to $700K per line. Teardown cost - $150K $175K Domestic packaging cost - $20K 30K Domestic shipping cost - $20K 30K International packaging cost $50K $75K International shipping cost $60K 90K Commissioning cost. $200K - $300K 7/2/2017 Celestica Page 2 of 45
3 Asset Overview Lines 1 & 2 Each 280 MW (Nameplate producing 335W modules) Semi automated PV Module production line currently occupies 28,000 square feet, and produces 240 MW of panels per year assuming 24/7 350 day operation running at 85% utilization. The factory has various points of automation and it takes about 33 operators to run production on the line producing 1950 modules per day at utilization. The factory is capable of handling 60 and 72 cell modules with glass/backsheet or glass/glass configuration. Line 1 is fully capable of producing up to 5bb modules, while line 2 requires a stringer tooling upgrade beyond 4bb. The line also has pre and post lamination EL. Major assets are photographed and listed below. If additional information is required please contact Liquidity Services at CelesticaSolarPrivateTreaty@LiquidityServices.com 7/2/2017 Celestica Page 3 of 45
4 Line Staffing Overview (Line 1) A 6 7 A A 5 A A 8 2 A A A Other staff Note : This is staffing Celestica has used to run the line. The staffing can vary by product, and additional steps required. 7/2/2017 Celestica Page 4 of 45
5 Line Staffing Overview (Line 2) A 8 A A 5 A A 2 9 A A A Other staff Note : This is staffing Celestica has used to run the line. The staffing can vary by product, and additional steps required. 7/2/2017 Celestica Page 5 of 45
6 Line Staffing Overview (Lines 1 and 2) Front End Process 4 Operators 1 - Loading glass 2 - Prep label and place template 3 & 4 - Managing stringer system 1 and 2 Central Process 7 Operators (A Additional Manual stations can be used as needed or for training) 5 - Loading busbar soldering template (J-Box side) and insulator 6 - Loading busbar soldering template (Non J-Box side) 7 & 8 - Remove busbar soldering template, and adjust insulator and label 9 - EVA and backsheet adjustment (after machine placement) 10 - Verify EL failure 11 & 12 - Cell repair 7/2/2017 Celestica Page 6 of 45
7 Line Staffing Overview (Lines 1 and 2) Back End Process 20 Operators 13 & 14 - Post Lamination Inspection 15 - Trimming 16 & 17 - Frame Sealant Dispensing (and Frame Loading) 18 - Frame Loading J-Box dispensing and attach 22 - Inspection and Cleaning 23 - File Frame Corners 24 - Install J-Box Cover and attach contact box 25 - Verify EL2 results and remove contact box Final Inspection 27 - Unloading the modules (Binning) 28 - Attach Labels (Binning) Other area X Operators 29 - Maintenance Tech Quality Tech. 31 & 32 - Material Handler/Material loader (EVA/Backsheet) 33 - Production Supervisor. 7/2/2017 Celestica Page 7 of 45
8 Line Layout / Factory Overview Line 1) 15. Curing 14. Potting 13. Cleaning 1. Glass wash Start 2. 1st EVA cut & place 280 MW Capacity 28,200 ft2 Floor Space 3. Tabbing, Stringing & Layup 16. Hi-pot test 4. Bussing 17. Flash & EL2 18. Binning 12. Jbox attach/ soldering End 5. 2nd EVA, Backsheet/2 nd glass cut & place 6. EL1 11. Crimping 7. Lamination 10. Framing 8. Inspection 9. Trimming 7/2/2017 Celestica Page 8 of 45
9 Line Layout / Factory Overview (Line 2) 3. Tabbing, Stringing & Layup 2. 1st EVA 1. Glass wash 13. Cleaning 14. Potting Start 280 MW Capacity 28,200 ft2 Floor Space 15. Curing 4. Bussing 16. Hi-pot test 5. 2nd EVA, Backsheet/2 nd glass cut & place 6. EL1 End 17. Flash & EL2 18. Binning 12. Jbox attach/ soldering 7. Lamination 11. Crimping 10. Framing 8. Inspection 9. Trimming 7/2/2017 Celestica Page 9 of 45
10 Manual Glass Loading Manually feeding cover glass to the front of the line. Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 10 of 45
11 Washing machine for glass Wet and Dry Wash Option Wet wash = washing with water Dry wash = air blowing with air knife Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 11 of 45
12 1 st EVA in-line cut and place machine An EVA cut and place machine plus a crane (250kg max.) for EVA roll loading. Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 12 of 45
13 FILO Vertical Buffer Maximum capacity is 30 panels. Machine quantity = 6 per line (3 at pre-lamination and 3 at post lamination) 12 in total. 7/2/2017 Celestica Page 13 of 45
14 Stringing Closed loop induction soldering, Mono/Poly, PERC and Bifacial cell compatible. Komax XCELL X3. Machine quantity = 4 per line, 8 in total. 7/2/2017 Celestica Page 14 of 45
15 Auto Inspection and Layup Each system has a string vision system, ribbon cutting and a KUKA placement robots. Machine quantity = 2 per line, 4 in total. 7/2/2017 Celestica Page 15 of 45
16 Manual busbar soldering (AKA Bussing) Operators place the busbars on the panel using template. Busbars are soldered onto the strings by hand-soldering. (production can be handled on the semiautomated line so the manual line is for extra capacity or training) Machine quantity = 1 line per line, 2 in total. 7/2/2017 Celestica Page 16 of 45
17 Automated Busbar Soldering Operators place busbars and template on the panel before loading into this ATN machine. This machine induction solders the busbars to the panel. This is upgraded for 4 and 5 bb Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 17 of 45
18 2 nd EVA and backsheet cutting machine EVA Backsheet This machine can handle a roll up to 250 KG Machine quantity = 2 per line, 4 in total. 7/2/2017 Celestica Page 18 of 45
19 2 nd EVA and backsheet or 2 nd glass placement machine Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 19 of 45
20 EL-1 Test (Pre-lamination) This machine can do a fully automated EL inspection of the module at a 64 mega pixel resolution. In the event of a fail, the machine notifies the operator for acknowledgment. If the operator overrides the call the module proceeds to the next step. If the operator fails the call, the module exits the conveyor and prints out the fail information for repair. Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 20 of 45
21 Lamination The line has three Burkle 2141 VFF laminators. The above picture shows a group of 3. The Laminators have a platen size of 2.1 m x 4.1 m and can accept four 60 cell modules per cycle or four 72 cell modules per cycle. All laminators also have active cooling where the modules are cooled under pressure reliving any stress in the module. Machine quantity = 3 per line, 6 in total. 7/2/2017 Celestica Page 21 of 45
22 Post lamination Inspection Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 22 of 45
23 Trimming 2 manual trimming stations per factory, requires one operator each. Machine quantity = 2 per line, 4 in total. 7/2/2017 Celestica Page 23 of 45
24 Frame sealant dispenser Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 24 of 45
25 Framing This framer can handle both loose fit and tight fit corner Machine quantity = 2 per line, 4 in total. 7/2/2017 Celestica Page 25 of 45
26 Crimping This is a fully automated crimping system to crimp the frame corners Machine quantity = 2 per line, 4 in total. 7/2/2017 Celestica Page 26 of 45
27 Plasma Treatment for J-Box (Line 1 only) This machine is used to treat the Junction box if required Machine quantity = 1 in total. 7/2/2017 Celestica Page 27 of 45
28 Junction box (AKA J-box) Sealant Dispensing Machine quantity = 2 per line, 4 in total. 7/2/2017 Celestica Page 28 of 45
29 J-Box attach and soldering Machine quantity = 4 per line, 8 in total. 7/2/2017 Celestica Page 29 of 45
30 Cleaning and Inspection Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 30 of 45
31 Filing (frame corners only, vary by product) Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 31 of 45
32 Potting This is a automated potting system Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 32 of 45
33 Curing This is a automated curing system with 11 stacks holding up to 3-4 hours of production. Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 33 of 45
34 Hi-Pot Test Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 34 of 45
35 Flash and EL Test The flash tower has a integrated EL system in the tower. Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 35 of 45
36 Unloading panel and binning Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 36 of 45
37 Off-line cutter (EVA and Backsheet cutting) This is a off-line machine that can be used as a spare or for development work. This machine can handle a roll up to 250 KG Machine quantity = 1 in total. 7/2/2017 Celestica Page 37 of 45
38 Off-line framer This is a off-line machine that can be used for development work without interrupting production. Machine quantity = 1 in total. 7/2/2017 Celestica Page 38 of 45
39 Off-line string repairing station Heating desk for 60 and 72-cell string repair. Machine quantity = 3 in total. 7/2/2017 Celestica Page 39 of 45
40 Off-line pull test machine To measure the pull force of the solder joint between the cell and the ribbon. Machine quantity = 1 per line, 2 in total. 7/2/2017 Celestica Page 40 of 45
41 Off-line EL inspection Off-line EL machine that can be used for analysis or development work. Machine quantity = 1 in total. 7/2/2017 Celestica Page 41 of 45
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