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					</table>India has made significant headway in expanding its solar module and cell manufacturing capacities over the years. However, a globally competitive manufacturing ecosystem also requires a robust domestic supply chain for balance-of-system (BoS) and bill-of-materials (BoM) components, such as junction boxes, connectors, cables, and aluminum frames.
According to Srivatsa, General Manager, Sales and Technical Operations at <a href="https://www.genxpv.com/" target="_blank" rel="noopener">GenX PV</a>, the biggest advantages of India’s domestic manufacturing ecosystem are shorter lead times and easy access to technical support. Additional financial and policy support could pave the way for a scale-up in the domestic solar component manufacturing ecosystem.
In an interview on the sidelines of the <a href="https://www.mercomindia.com/event/mercom-india-renewables-summit-2026" target="_blank" rel="noopener">Mercom India Renewables Summit 2026</a> on July 1 and 2 in New Delhi, Srivatsa shared his insights on localization, backward integration, domestic manufacturing, policy support, and the future of India&#8217;s solar component ecosystem.
Edited excerpts from the interview:
India has made significant progress in module and cell manufacturing. How important is it now to strengthen the domestic manufacturing of BoS and BoM components?
If you look at the industry today, India has installed module manufacturing capacity of more than 200 GW. With around 30 GW of operational capacity, cell manufacturing is catching up rapidly, and several new projects have been announced.
For junction boxes, India already has around 120-150 GW of domestic manufacturing capacity. We are seeing a clear shift from imported products to domestically manufactured components.
One of the biggest advantages of manufacturing in India is shorter lead times and readily available technical support. If any issue arises in the field, our engineering teams can visit the site and resolve it much faster than imported suppliers can.
GenX PV has expanded from manufacturing junction boxes and connectors into aluminum frames. What drove this backward integration strategy?
Backward integration has always been part of our long-term strategy.
We started with junction boxes and subsequently integrated plastic molding. We are now moving towards cable manufacturing. Over the coming years, we plan to expand to diode manufacturing. Our objective is to establish an integrated manufacturing facility where all these components are produced under one roof.
We identified aluminum frames as another opportunity because domestic manufacturing capacity in this segment is relatively limited. We plan to establish a complete manufacturing chain, from aluminum billets and extrusion to finished module frames.
Backward integration improves cost competitiveness while providing better control over quality and delivery timelines.
Today, the pricing difference between domestic products and Chinese imports has narrowed considerably. The larger concern is product dumping rather than manufacturing competitiveness.
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Do you believe that India can localize the entire solar components ecosystem within the next few years?
Absolutely. For junction boxes alone, localization has already reached around 50% to 70%.
The remaining components, particularly diodes, will require additional investment and time. Over the next two years, we expect manufacturers to continue integrating backward and substantially increase localization across the value chain.
How competitive are domestically manufactured components compared to Chinese products?
From a manufacturing perspective, we are already competitive with Chinese suppliers.
The challenge arises when products are dumped into the Indian market at artificially low prices.That is where additional policy support could help domestic manufacturers compete on a more level-playing field.
What kind of policy support would benefit component manufacturers?
Junction boxes are among the few component categories for which policy protection remains limited. Currently, they attract only a 7.5% Basic Customs Duty (BCD), unlike components such as encapsulants, backsheets, or solar glass, where stronger protective measures already exist.
Additional policy support would encourage further domestic investment and accelerate manufacturing scale-up.
Module technologies continue to evolve toward TOPCon and HJT. How is GenX PV adapting to these technology transitions?
Our product portfolio has evolved with module technologies. We currently manufacture junction boxes supporting current ratings from 20 A to 35 A, covering conventional monocrystalline modules, TOPCon, M10, G12, HJT, and other advanced technologies.
We are also prepared for higher system voltages. Our products are already designed for applications up to 2,000 VDC, reflecting the way the industry is moving beyond the traditional 1,500 VDC standard.
Continuous investment in research and development enables us to keep up with evolving market requirements rather than reacting after technologies are commercialized.
Beyond financial incentives, what additional reforms would strengthen India&#8217;s component manufacturing industry?
A key area is the mandatory use of Bureau of Indian Standards (BIS)-certified DC cables. While several large projects already specify BIS-certified cables, currently there is no universal requirement across the industry.
Making BIS-certified cables mandatory would improve product quality, strengthen domestic manufacturing, and create a more uniform market for Indian suppliers.
How do you see India&#8217;s BoS component manufacturing industry evolving over the next few years?
The industry is expanding rapidly. As annual solar installations continue to increase, more domestic manufacturers are entering the market and building local production capacity.
Although component manufacturing still has room for growth, we expect domestic participation to increase significantly over the next two to five years.
How is the relationship between module manufacturers and domestic component suppliers evolving?
Initially, there was considerable resistance because module manufacturers had relied on imported components for many years.
Changing established procurement practices takes time.
However, once manufacturers began using domestically produced components and observed their field performance, their confidence gradually improved.
Being an Indian manufacturer gives us an important advantage. We can provide technical assistance, engineering support, and after-sales service whenever required.
Our products comply with all relevant IEC and BIS standards, undergo additional in-house testing, and have performed reliably in the field over the past five years. That performance has helped build customer confidence.
How do you ensure your products can withstand India&#8217;s diverse climatic conditions?
Every junction box is designed to operate under a wide range of environmental conditions. We conduct extensive temperature cycling and environmental testing to ensure reliable operation regardless of whether the modules are installed in Rajasthan, Karnataka, or any other climatic region.
These qualification tests ensure long-term reliability under real-world operating conditions.
What are GenX PV&#8217;s growth plans over the next five years?
Our primary focus is backward integration.
Today, we have nearly 50 GW of junction box manufacturing capacity. Plastic molding has already been integrated, cable manufacturing will commence shortly, and diode manufacturing will follow.
All these operations will eventually be consolidated into an integrated manufacturing facility in Bengaluru.
We are also expanding into aluminum frame manufacturing. Beyond that, we will evaluate additional diversification opportunities as the market evolves.
Do you believe India can establish a fully integrated domestic solar manufacturing ecosystem?
Yes, I believe we are already well on our way.
Most of the BoM components required for junction box manufacturing are already produced domestically.
The remaining challenge is scaling the capacity to meet growing demand.
Consistent government policy, without major changes or reversals, will enable manufacturers to invest with confidence and accelerate the development of a fully integrated domestic manufacturing ecosystem.

Domestic Solar Component Manufacturing is Ramping Up Fast: Interview

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					</table>In an interview on the sidelines of the Mercom India Renewables Summit 2025, Chetan Amrutkar, Assistant Vice President (Sales) at <a href="https://genxpv.com/" target="_blank" rel="noopener">GenX PV</a>, stated that the government needed to support solar component manufacturing for it to grow in parallel with domestic module manufacturing. He said localization mandates will help the manufacturers of junction boxes, cables, and diodes to grow faster.
Amrutkar also spoke about his competition from imports, his company’s plans for capacity expansion and diversification, and its plans to tap public markets through an initial public offering.
Could you provide an introduction to GenX PV? 
We are a Bengaluru-based company. We manufacture solar PV junction boxes and connectors. We have 20 GW of manufacturing capacity located in Bangalore. We are a fully automated manufacturing facility, and our products are tested thoroughly to ensure they perform optimally for 30 years.
How do you view the manufacturing landscape for Balance of Systems (BoS) components in India? 
Over the last four or five years, solar manufacturing, particularly in module production, has experienced significant growth. The module capacity under the Approved List of Models and Manufacturing has grown to about 100 GW.
There is also a huge scope for BoS component manufacturing.
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How does Indian BoS component manufacturing compare with imports? 
We have very strong competition on the price front from imports. However, domestic manufacturing capability under the Make in India initiative is now growing. Essentially, our USP lies in manufacturing high-quality products. We continually engage with our customers to resolve any issues that may arise.
Many of the imported panels and junction boxes fail in the field. Our developers and independent power producers lose a significant amount of generation hours due to such products. We provide them with local support, which they often lack when importing products.
With imported components, even obtaining warranty support on time can be a challenge.
What kind of support are you getting from the government in terms of any incentives or tax breaks?
Currently, we are not receiving any support, which is significantly hindering our growth. We don’t have good profit margins because we have to compete directly with Chinese suppliers.
Solar cells and modules protection from imports with the Approved List of Models and Manufacturers in place. We also need some similar support. That will really help us grow.
Have there been any talks with the government regarding such concessions or incentives for junction boxes and other BoS components? 
We haven&#8217;t had any talks so far because we are currently building our capacities. Once we have enough capacity, we can then approach the government. Solar manufacturing capacity is growing at a very rapid pace. Therefore, the BoS component segment will also need to grow in parallel.
It would also help if the government mandates a certain percentage of local BoS content in tenders.
However, some policy support specific to components is definitely crucial going forward.
What kind of support are you getting from the states? 
We have committed an investment of ₹9 billion in Karnataka. We are hopeful of receiving some kind of support, both from the state and the central government, as we are also creating jobs.
Do you think the industry has the workforce with the skills to perform all these jobs that the component manufacturing space is creating?
When we started GenX PV, component manufacturing was very new. Unlike module manufacturing, there is very limited manpower available. We have been training them at the manufacturing level, as well as in quality control and lab testing. We deploy automated machines, but to operate them effectively, we need to dedicate a significant amount of time and manpower to realize their full potential.
Is the machinery for component manufacturing being produced in India, or do you have to import it?
Automation is very complex. Currently, 90% of the machinery is imported. We are trying to localize the maintenance part.
What are the future plans of your company? 
We plan to expand our capacity from 20 GW to 50 GW in the next two years. Apart from that, we are pursuing backward integration. We will go into cable manufacturing and set up diode assembly lines. We already have some injection molding capacity. We are also planning to diversify into other components, such as aluminum frames.
What type of investment are you considering for the expansion plans?
As I mentioned, we have already committed ₹9 billion to Karnataka, which we will invest over the next two to three years. We will tap the markets with an initial public offering next year. We will probably be the first company in this space to go public.
How do you see the renewable energy industry moving forward in the next five years? 
If we can overcome land constraints and augment the grid infrastructure, we should plan to reach 2,000 GW by 2035. Solar will have a big share because it is one of the easiest ways to expand renewable energy capacity, due to the short project timelines.
We are heavily dependent on one country for technology, so we need to reduce our dependence on it.
Are there any certification standards for BoS components? 
We have to conform to the Bureau of Indian Standards (BIS) and IEC specifications.  BIS will also become mandatory for cables. Going forward, we hope that all components will also be subject to BIS certification, in addition to the PV modules.
(Note: Sections of the interview have been paraphrased for better reading. Check out the video for a full chat)

Lack of Government Support Slowing Growth of BoS Manufacturing: Interview

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					</table>Solar manufacturers can reduce costs and minimize quality defects in cells and modules, and balance of system components by using AI and automation.
A panel discussion titled ‘Technology Innovations Driving Efficiency, Profitability, and Competitiveness in Renewables,’ held on July 24, 2025, at the <a href="https://www.mercomindia.com/event/renewables-summit-2025/register" target="_blank" rel="noopener">Mercom India Renewables Summit</a> 2025, shed light on the technological developments in solar manufacturing including the use of AI.
Industry experts Vikram Kenjale, Vice President (India) at <a href="https://www.gamechangesolar.com/" target="_blank" rel="noopener">GameChange Solar</a>; Chetan Amrutkar, AVP of Sales and Marketing at GenX PV; and Sumit Kumar, Vice President of Operations (Manufacturing) and Technology at <a href="https://www.vikramsolar.com/" target="_blank" rel="noopener">Vikram Solar</a> shared their insights on the topic.
Sishir Garemella, Head of International Business Development at <a href="https://scorecard.pvel.com/" target="_blank" rel="noopener">Kiwa PVEL,</a> moderated the session.
Kenjale of GameChange Solar said that multiple factors contribute to module failures. “We follow IEC standards, and have third-party testing to confirm the compatibility of the modules. We do unbalanced testing of modules, wherein it tests real-time scenarios in the event of a wind/storm.”
He added that for their trackers, they have two sets of purlins; the exterior purlin acts as a shield for the interior array layout, which helps reduce module failures.
Amrutkar of GenX PV said that the advancements in solar module technology are impacting the growth of junction box manufacturing. The company has a 20 GW in-house manufacturing facility, and plans to reach 50 GW in two years.
“For TOPCon, we have 30 ampere junction boxes for G12 and G12, and we have 35 ampere junction boxes because the ICC/IMAX ratings are increasing,” added Amrutkar.
Amrutkar highlighted that automation is reducing errors in the manufacture of junction boxes.
“Earlier, the junction box was manually installed on the module and then soldered.  Now, the entire set of junction boxes is picked automatically and placed at the right locations. Simultaneously, the soldering, potting, and cap fixing happen automatically,” he added.
He said GenX PV had altered the junction box design to enable the movement of the automation arms.
Amrutkar noted that these measures have reduced GenX PV’s production costs and increased the efficiency and reliability of their products.
“We select the right raw materials and diodes for junction boxes. In imported junction boxes PV modules, the selected junction box rating and selected diode ratings are very close to the module rating. We are using much bigger diodes for the forward current. This minimizes overheating of the diode which is one of the key reasons failures in junction boxes,” he said.
He added that GenX PV also tests its components to 3 IEC standards to ensure its components can withstand extreme climatic conditions and performance conditions in the field.
Utilizing AI in Testing
Rayzon’s Barve said that for its 6 GW model manufacturing plant, it has been working on backward integration with aluminium extrusion, and an anodizing unit of 19,800 metric tons per annum.
He revealed that the company also has plans to set up a TOPCon cell line of 3.5 GW in the next financial year.
Barve said that AI is primarily being used for quality testing of solar modules and cells.
“We have a two-three-stage process in model manufacturing where inspection needs to happen on a very regular and stringent basis. Earlier, numerous checks, including EL imaging at the string and module level, and EL imaging post-lamination, were done manually. This has been fully automated. If there is any ambiguity, then an operator comes into the picture to take a final call,” he said.
With the integration of AI in the quality check process, there is now little possibility of human errors.
Barve said AI, coupled with machine learning and machine vision, is being utilized from the start of the manufacturing process through to the assembly lines. “If there is any problem with the cell, the cell gets rejected.”
He said newer manufacturing lines are built with AI integration, making the manufacturing process more accurate.
Upcoming Technology
Vikram Solar’s Kumar added that TOPCon is front frontrunner because its Levelized Cost of Energy (LCOE) is the lowest today.
“Irrespective of other technologies in the market, TOPCon holds around 70% of the market share. Today&#8217;s LCOE is with TOPCon&#8217;s future is definitely with TOPCon with the back contact. TOPCon G12R format will have a longer life than TOPCon with back contact. Perovskite in a tandem form, either with heterojunction or TOPCon, will be the front runner probably three years later from now,” added Kumar.
Talking about solar trackers, Kenjale highlighted how AI is making them weather-smart.
In terrains that require grading, the company inputs topography data from the ground, which is integrated with software to provide a master controller that can give commands to different nodes.
“It sends different commands to individual nodes so that trackers can adjust themselves to avoid the shadow effect on the previous or backward tables. On an annualized basis, it will give 5- 5.5% additional gains,” he said.
Kenjale added that on cloudy days, their solar trackers can be optimized to work without direct sunlight.
“We define a threshold, and when it reaches that threshold, the system maximizes the diffused sunlight that is coming on to the modules. Thereby, you can increase the energy gain. It can also give 6.5% additional gains,” added Kenjale.
Need for Green Skilling
The panelists highlighted the dearth of skilled labor to manufacture build solar components.
Barve said that the entire science and technology related to solar manufacturing needs to come to the academic side as soon as possible.
“We should look at engineering colleges with specialised branches for solar energy. We have also been a bit slow in terms of tapping our existing R&amp;D potential. We see a lot of brain drain due to this issue,” he said.
He said India is completely dependent on imports to establish manufacturing facilities. “With hundreds of gigawatts to be manufactured in India without equipment being made in India, our dependency remains high on imports,” Barve said.

AI-Integrated Manufacturing Will Boost Quality and Reliability of Solar Products

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