India’s solar energy ambition is staggering. The government has set a target of 500 GW of renewable energy capacity by 2030, with solar accounting for the bulk of the expansion. Driving this transition is not just installation activity — it is a parallel revolution in domestic solar manufacturing, particularly in solar cell and module production. For distributors and installers serving PM Surya Ghar and PM Kusum, understanding how solar cells are made in India — and which manufacturing steps affect panel quality — is essential for making informed procurement decisions.

The Solar Cell Manufacturing Process: A Step-by-Step Overview

Step 1: Silicon Ingot and Wafer Production

Solar cell manufacturing begins with high-purity polysilicon, which is melted and grown into single-crystal silicon ingots using the Czochralski (CZ) process for monocrystalline silicon. These ingots are then sliced into ultra-thin wafers using diamond wire saws — currently standardised at 182 mm × 182 mm (M10 format) for leading Indian manufacturers.

Step 2: Cell Processing — Diffusion, Passivation, and Metallisation

The wafer undergoes a sequence of chemical and thermal processes: surface texturing to improve light trapping, diffusion to create the p-n junction that drives the photovoltaic effect, and anti-reflection coating (ARC) deposition. For Mono-PERC cells, an additional rear-side passivation layer is applied — this is what defines the PERC (Passivated Emitter and Rear Cell) architecture and accounts for its efficiency advantage over standard BSF (Back Surface Field) cells.

Finally, silver and aluminium contacts are screen-printed and fired at high temperatures to form the cell’s electrical connections. This metallisation step is critical — the precision of silver paste deposition directly affects cell efficiency and long-term degradation rates.

Step 3: Quality Testing and Binning

Every cell is tested under a Solar Simulator under Standard Test Conditions (STC: 1000 W/m², 25°C, AM 1.5G spectrum). Parameters measured include open-circuit voltage (Voc), short-circuit current (Isc), maximum power (Pmax), fill factor (FF), and efficiency (η). Cells are sorted (binned) by power output — typically in 0.1 W bins — to ensure matched cells are used in each module for consistent performance.

What Makes a High-Quality Solar Cell?

Not all solar cells are equal, even from the same manufacturing line. Key quality indicators that distributors should understand include:

Low Light-Induced Degradation (LID): In p-type mono silicon cells, boron-oxygen defects can cause initial efficiency loss of 1–3% in the first weeks of light exposure. Premium manufacturers use LID mitigation techniques including light and elevated temperature annealing processes.

Low Potential Induced Degradation (PID) Resistance: PID can cause significant power loss in field conditions due to leakage current. High-quality cells and encapsulants are designed to resist PID, which is particularly important for large ground-mounted PM Kusum installations where system voltages are high.

Tight Efficiency Distribution: A narrow spread (tight binning) within a production batch ensures consistent module output and minimises mismatch losses in strings and arrays.

India’s Solar Cell Manufacturing Landscape

India’s solar cell manufacturing capacity has grown substantially, with several established manufacturers producing cells across the M6 and M10 wafer formats. For a complete overview of the manufacturers operating in this space, refer to our guide to solar cell manufacturers in India.

Websol Energy System has been manufacturing solar cells in India since 1994 — among the earliest entrants in the Indian solar cell manufacturing space. Operating from its advanced manufacturing facility in Falta, West Bengal, Websol produces M10 Bifacial Mono-PERC cells that serve the quality requirements of both domestic government schemes and export markets. Visit our solar cell manufacturer in India page for technical specifications.

The PLI Scheme and Its Impact on Solar Cell Quality

The Production Linked Incentive (PLI) scheme for solar PV manufacturing — managed by the Ministry of New and Renewable Energy — provides financial incentives to manufacturers who achieve high efficiency thresholds and domestic sourcing percentages. This has driven Indian manufacturers to invest in higher efficiency cell technologies and tighter quality control, ultimately benefiting distributors and installers who source from PLI-participating manufacturers.

To understand the broader trajectory of Indian solar manufacturing, read our analysis of the future of solar manufacturing in India — technology, policy, and growth trends.

Why Domestic Solar Cells Matter for PM Kusum and PM Surya Ghar Installers

Both PM Kusum and PM Surya Ghar prioritise domestically manufactured modules through ALMM compliance and DCR requirements. Sourcing from a domestic solar cell manufacturer directly reduces supply chain risk — no import delays, no customs compliance issues, and full traceability of the manufacturing process for government audits.

Additionally, domestic manufacturers can provide technical support, rapid replacement in warranty situations, and documentation that meets MNRE’s evolving compliance requirements — advantages that imported modules simply cannot match at scale.