Solar module manufacturing is a tedious process, which consumes many raw materials. There are many steps involved until the finished ready to be sold panel is manufactured. As East and Southeast Asia are the largest hub of solar module manufacturers, the solar panels are required to be transported to a long distance, as the consumers are located at different geographical locations across the globe. This transportation can take place via many means. As solar panels are high priced, it is important to carry out safe and efficient packaging of the solar panels so that the panels will not be damaged during the shipping. Sometimes panels reach out to the consumers with cracks, deformation or scratches because of improper packaging. Improper packaging of solar modules can result into a huge financial loss. There are many incidents where the panels were dispatched in good condition from the factory but it is damaged on the way. This result into claims and disputes between the consumers and manufacturers. Therefore, safe packaging of solar modules is very important aspect of the industry, which is often ignored.
Basics of Solar module packaging:
There are two types of solar panel packaging: vertical and horizontal. Solar modules are stacked together in a vertical or horizontal box. Generally, corners of each modules are covered for protection and separators are used between each module. Sometimes, each module is packed in individual boxes and then all the boxes are packed in a single master carton box to ensure the safety of modules. The master box pallet is then after sealed and wrapped with plastic film. Then, solar panels are shipped holding on pallets, average 28-30 panels per pallet.
An important thing to notice about packaging, transporting and unloading the solar modules that there is no standard, which is globally accepted. The biggest hurdle in establishing a global standard is different client requirements. When products and requirements of the client varies from case to case, it is not possible to frame a global standard for the safe packaging. Additionally, packaging is one of the way to cut down the overall cost, many manufacturers compromise heavily on the packaging material and qualified packaging personnel.
The next step in the designing the toughest solar packaging is by optimising the thickness of the cardboard boxes. We make sure that the cardboard boxes are thick and rigid, with corner supports that can resist huge pressure. The cardboard box must be capable to withstand the weight of all the solar modules, so that if another full pallet is stacked on the top of it, the box should not be deformed. When we stack the pallets of panels on the top of each other, no stress is exerted to the bottom solar modules because of the higher quality of cardboard box, which allows customers to receive the solar panels in perfect condition. A qualified packaging design would maintain perfect form when any pallet is stacked on the top of it. With visual inspection also, packaging personnel can identify the deformed boxes.
Issues with Bad Packaging
When solar modules are stacked on the top of each other, it can cause stress on the modules, which may damage the modules. Although, sometimes the damages are not visual but they are in form of micro cracks that can even grow in future and may deteriorate the performance of the modules. When modules are packed horizontally, the panels are separated with carton separators. When it is required to pack the modules horizontally, it is essential to have good buffer materials between each module and around the modules to reduce the chances of damages.
Dangers in transportation & loading
When modules are shipped via a long journey, it is essential that modules must be properly packed to ensure their safety. Although the method of transport used is not standardized, it does involve a great deal of risk. In addition to the risks of improper handling, modules can become damaged during shipment. Solar panel’s weight is also one of the constraint along with its size. Sometimes, transporters underestimate this factor, which may result into a hazardous situation. If modules are improperly packed, then mechanical stresses may arise which may damage the modules. Sometimes, during loading and unloading, workers walk or stand on the panels, which is not recommended at all. Many a times during long road journey, improperly packed modules on a pallet gets bounce(s) while being carried in a truck on a bumpy road or in a ship in the wavy sea. Many a times, the manufacturer packs modules in a proper way and they are forwarded to the shipping companies. Shippers may store the panels in warehouse in improper way or they may follow improper methods to load the panels. Careless workers may also damage the panels in the forklift operation which may result into visually noticeable dents or cracks on the panels.
That is why it is essential to follow unpacking and unloading instructions thoroughly to ensure panels’ safety and performance. Safe, correct and careful packaging of solar modules is as important as manufacturing them. There will be a global standard in upcoming time which every manufacturer will adhere. Until then, utmost cautiousness must be shown in packaging, loading, unloading, transporting of modules.
