BC structures can be applied to various types of cells, including TOPCon and HJT, to enhance cell efficiency. BC solar cells have the potential to achieve efficiencies of up to 29.1%, recognized as the highest performance potential among all known silicon solar technologies. However, manufacturing bifacial cells presents a greater challenge. Increased production on the front side of IBC may not justify the higher costs compared to TOPCon.

Balachandar Krishnan, COO of the solar cell manufacturing plant at Indosol Solar, stated that BC solar cells may not capture at least 10% of the market share by 2028. He pointed out several key barriers to IBC adoption, including high capital costs, non-standardized processes with varying pathways, and increasing operational costs. Reliability issues, lower yields, and increased electrical rejection and failures due to manufacturing complexities also present challenges.

Additionally, the bifacial factor of BC solar cells is 70%, while TOPCon cells have an 80% factor. These figures indicate that BC cells can absorb 70% of the light received from their rear side, while TOPCon cells increase this ability to 80%. In other words, bifacial TOPCon cells absorb light more effectively from both the front and back, generating more energy, which may impact the difficulty of adopting BC technology.

Gyanesh Chaudhary, chairman and CEO of Vikram Solar, stated that cost sensitivity in the Indian market means the overall cost of solar energy, per watt-peak of panel production capacity, is critical. Currently, BC technology involves complex processes and high investment. This technology is still in the development stage, with more advancements expected by 2025.

 

Preparing for Transition

 

Until BC technology becomes established as a more viable option, manufacturers prefer to focus on existing processes in their production lines to enhance cell efficiency. However, many solar panel manufacturers have included BC technology in their technology roadmaps, as several leading module manufacturers in India have indicated to pv magazine.

Krishnan from Indosol said, “For tier-1 solar cell suppliers, TOPCon has achieved 26% efficiency by introducing the LECO [laser-enhanced contact opening] process and using edge passivation as a standard process in their production lines.” In this context, Krishnan believes that TOPCon still has greater potential to exceed 28% efficiency in cells by adopting a range of innovations.

He added, “With this clear-cut roadmap in mind, manufacturers will focus on leveraging the maximum potential from existing TOPCon lines rather than on a newer technology that has yet to be proven in mass manufacturing in terms of cost, yield, and reliability.”

While some manufacturers may adopt BC technology earlier, understanding and leveraging the aforementioned possibilities for TOPCon should keep this technology competitive in the medium term. Juhi Marwadi, director of module maker Pixon, stated, “With back-contact routes promising even higher efficiencies than TOPCon, Indian manufacturers must focus on integrating advanced techniques like selective doping, light trapping, and surface passivation. This will help them remain competitive in the global market as other manufacturers also shift to high-efficiency cells.”

Regarding the transition to BC, government incentives, technology partnerships, and workforce training are essential to facilitate the process.

Marwadi stated, “Manufacturers need to assess their existing production lines and understand the degree of compatibility for future BC manufacturing.” She explained that this assessment includes optimizing processes such as contact printing, passivation, and module assembly, among other aspects. To ease the transition to BC, Marwadi anticipates that Indian manufacturers will seek partnerships with international tech companies and research institutions specializing in BC solar technology. Such collaborations could accelerate the technology transfer process and reduce the learning curve for new approaches. She also noted, “Manufacturers will need to invest in upskilling their workforce to manage the more advanced IBC processes.” Marwadi concluded by mentioning that the Indian government’s PLI [production-linked incentive] scheme and other solar industry incentives might provide the necessary financial support for manufacturers transitioning to next-gen technologies like IBC.

Hardip Singh, COO of Grew Energy, stated that the rapid pace of technological advancements in the solar industry poses a significant challenge for Indian manufacturers. The rate of return on investment in manufacturing technology often lags behind these advancements. Singh predicts that this trend will continue, requiring manufacturers to either adapt to new conditions or find innovative solutions. He also noted that manufacturers have already sought government support to address this issue.

 

Suhas Donthi, president and CEO of Emmvee Group, stated, “With the anticipated transition to BC panels as early as 2025, we are closely monitoring the advancements in BC technologies. We are prepared to introduce these cutting-edge solutions to the Indian market when they reach the right stage for large-scale commercial deployment.”