www.pufinpower.com
M a a s t r i c h t
EN
PUFIN POWER Pufin Power is an integrated and internazionalized industrial Holding that works mainly in the photovoltaic sector having inside its own production of PV cells (SOLLAND Solar Cells – The Netherlands– Germany), PV modules production (EL.ITAL.- Italy ; ELIFRANCE – France) as well EMS sector (Electronics Manufacturing Services) (EL.ITAL.- Italy; ELIFRANCE – France ). Personnel with high experience and Know how acquired during the Year in the sector; PV cells production with high efficiency
Achievements upon the market about its quality production as well as the brand of “Made Europe” Integration between electronics and solar energy. PUFIN POWER
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Products and services
Energy Division Polysilicon PV Cells PV Modules in polysilicon made with 60 and 72 cells
EMS Division Production of electronic boards and electrics systems Industrialization Services Logistic distribution and customer care
Prototyping and re-engineering
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Certifications The facilities have management systems conform to industry standardsoriented to a continuous improvement and customer satisfaction. Certification of Quality Management System ISO 9001 / EN 9100 / ISO TS 16949 Certification of the Environmental Management System, safety and health at work
BS OHSAS 18001 / ISO 14001 Participation in the PV-Cycle Management of End of Life Products Certification of Product / Process The photovoltaic products are developed and manufactured in accordance with established standards for electrical safety and for Approval of Type EN 61215:2005 / IEC 61215:2006 EN 61730-2:2007 EN13501 PUFIN POWER
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www.sollandsolar.com PUFIN POWER
SOLLAND SOLAR CELLS Heerlen (The Netherlands)
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SOLLAND SOLAR CELLS Solland Solar Cells BV is specialized in the production of Polysilicon PV Cells. The Facility makes use of a non- stop production lines with a full capacity of 135MWp/per year.
The equipments reflect the current level of production and allow to exploit this kind of technology respecting the strict rules in environmental and personal protection.
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PV cells production
PRODUZIONE CELLE FOTOVOLTAICHE
Production Lines perform 156 x156 mm polycrystalline Wafers carrying out the following phases: Wafer Optical Inspection: through robotized optical system, damaged wafer were isolated before processing thus maximizing the efficiency of the following phases. Superficial texturing: through the use of Hydrofluoric and nitric acids, it allows to make on the wafer a surface that maximized the capture of sunny radiation: Doping and diffusion: in this step is realized the N-P junction that allow the cells to work-. This step involves deposition of ortho-phosphoric acid controlled by ultrasound and phosphorus diffusion in Sylicon at high temperature by a furnace in continuous loop. Edge Insulation: in this phase is removed the residue ( called glass phosphor) products in the previous phase through a series of acid and basic baths. The insulation is separated by chemical way allowing the use of the energy produced. Anti reflex treatment: in this step a thin layer of Sylicon nitride is deposited so allowing to control the thickness with high precision thanks to the PECVD technique. Manufacture of electrodes: it is realized by depositing Aluminium and Silver metallization on the two sides of a cell in order to collect the electrical charges produced thus avoiding losses.
Classification: in this phase cells are measured one by one in order to characterize their electrical parameters and to test their functioning before their packaging and delivery.
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Layout manufacturing line
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EL.ITAL.
Avellino (ITALY)
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Site History 1974
Foundation of ITALDATA to strengthen existing collaboration between SIEMENS and STET (It. Gov.)
1975 – 1983
TLC Product evolution: - Automatic Fault Analyser for PSTN, μP controlled Modems, PCBA’s for “TUT-System” Informatic Products: - Manufacturing center of Power Supplies for Siemens Printers, HD Drive Unit for Siemens Mainframes (PCBA and final Assembly) TLC Products: Development and Manufacturing of Products oriented to Italian Telecom Market (Home Working for Telecom Services and Card Reader) Informatics Products: - Manufacturing of Midrange Computers and Optical Devices PC Siemens Assembly Plant
1984 – 1995
1995 – 1997 1997 – 2000
Complete Responsibility for the Siemens PC Consumer Business (up to 300.000 PC in 1999) including engineering, purchasing, manufacturing, distribution and service
2000
Flextronics overtaking the Avellino site
2001 – 2002
Improvement of EMS activity for PC Consumer market (MediaWorld and Uniero), Communication Devices (ADSL Router for Digicom)
2003 - 2004
EMS activity oriented to industrial market: Conditioning System Controllers , Door Hub Controller for Automotive, Electronic Meter for ENEL
2005
GRUPPO PUGLIESE overtaking the Avellino site. New Customers acquisition in the Defence and Medical market segments. Startup of the ENERGY project.
2009 2010
EL.ITAL. Avellino Srl becomes EL.ITAL.SpA Creation of Energy Division and startup of PV Modules manufacturing
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The Site Warehouse Maintenance
Plant
Offices
Warehouse
Factory
Total surface
(mq 70.000)
Local gross surface
(mq 10.968)
- thereof office area
(mq 2.100)
- thereof manuf. area (mq 5.425) Engineer. Refectory
- thereof warehouse area
(mq 2.193)
- thereof other functions (maintenance, facilities)
(mq.1.250)
External area Parking
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(mq. 2.700)
Manufacturing lines layout
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ELIFRANCE
Saint Etienne (FRANCE)
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Our History – For than 70 years !
•1941 – CRC Creation : “Constructions Radioélectriques du Centre” •1971 – Schlumberger overtaking of CRC
•1992 – Test activity development ) (Banking terminal, ATE..) •2003 - Flextronics overtaking of the factory and its activities •2010 - Pufin overtaking of the factory and its activities transforming Flextronics Saint Etienne in ELIFRANCE with the start of the Energy activity ELIFRANCE
•2011 - Start producing photovoltaic modules PUFIN POWER
ELIFRANCE Key Advantages Part of an international Group
• Revenue of site based on two
complementary activities Unique skills
• • • • •
In test and measurement In managing design partners In Box Build In building specific Electronic processes In dealing with international activities
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Layout with 1 PV Manufacturing Line Energy
EMS
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PRODUCTS
www.sollandsolar.com
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www.pufinpowerservices.com PUFIN POWER
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Pufin Power Services is the company of the group focalized on marketing/logistics products photovoltaic:
– PV Cells
SOLLAND SOLAR CELLS
– PV Modules
EL.ITAL. - ELIFRANCE
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Energy Division
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Energy Division’s Main Customers
Marone Impianti
LOGI.TECH
PAGEDIL
Furni Russi Srl
ANZ POWER
DENTRO IL SOLE
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A few examples of PV plants built using conventional EL60 - EL72 modules
Oppeano (VR) - c.a. 1 MWp – EPC: FAR SYSTEM
Acqualagna (PU) - Le Pole - c.a. 5 MWp - EPC: IMET San Benedetto del Tronto (AP) – Stadio Comunale EPC Troiani & Ciarrocchi
Montesarchio (BN) - c.a. 1MWp - EPC: ELIOSIS
Mottola (TA) - c.a. 1 Mwp EPC: SIEMENS
San Cassiano (LE) - c.a. 1 MWp - EPC: FIN POWER
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A few examples of PV plants built using innovative modules for Total Building Integration using “Capillary Comb” frames
Santa Palomba (RM) Potenza: c.a. 405 kW EPC: Logi.tech Srl
Jesi (AN) Potenza: c.a. 1.6 MW EPC: Piquadro Srl
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Montegrosso d'Asti (AT) Potenza: c.a. 710 kW EPC: TERMOCOMPONENTI Srl
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Main Equipment and Technological Systems
Automation and Control Optical Lines: Jonas & Redmann Texturing: Schmid Diffusion Furnace: Sierratherm
Insulation: Schmid SINA: Roth & Rau Screen printing: Baccini Furnace Firing: Despatch
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Illustration of the process
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Illustration of the process
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Illustration of the process
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Illustration of the process
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Illustration of the process
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Data sheet Cells
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Energy Division Manufacturing Lines
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Production Line Photovoltaic Modules Lines with maximum productivity of 40 MWp (3 shifts) Line 1 Washing machine
Sun simulator
Line 2
2 X Tabber / stringer :
2 X Laminator :
Teamtechnik TT900
- Maier Icolam 38/24
2 X Tape and Frame application
Productivity
Productivity
760 cells/Hour 13 panels/Hr (60 cells Panel)
Berger PSL-1000F
OCIMA
-Burkle Easylam Single Stage Productivity
1 X Testing :
Productivity > 32 panels/Hr
ďƒ˜13 panels/Hr
13 panels/Hr
2746 Wp / Hour
2746 Wp / hour
20.520 Wp/shift
20.520 Wp/shift
61.560 Wp/day (3 shift)
61.560 Wp/day (3 shift
20 MWp/year
20 MWp/year
>20 MWp/year (3shift)
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>45 MWp/year (3shift)
Manufacturing Lines Productivity Single PV Line to Max Manufacturing Capability
Line Description
Production/Year Production/Year Number (6 turni) 7 d/wk (3 shifts) 7d/wk of Lines
Assembly Line
20 MWp
40 MWp
2
Testing Facility
> 45 MWp
40 MWp
1
> 45 MWp
40 MWp
1
Other Equipment: Glass Washing machine Film Cutter EVA, Backsheeet) Ribbon Cutter PUFIN POWER
PV Turn-Key solution EL.ITAL. Is able to offer to the Customers not only High Quality PV Modules but other services in the PV Business as Preliminary Solar Plant Design, incentives administrative process follow-up, installation and after sales technical assistance for Solar Plant utilizing EL.ITAL. PV Modules. The EL.ITAL. Technical Dept can realize the Technical Project and the full Business Plan to help the Investors during the decision phase.
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Energy Division
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Production Line Photovoltaic Modules Line with maximum productivity of 25 MWp (3 shifts)
Tabber / stringer :
Laminator :
Teamtechnik TT1200
Burkle Easylam Double Stage
Tape and Frame application :
Testing : Berger PSL-1000T
OCIMA
Productivity 1200cells / hour
Productivity
Productivity
20 panels / hr (60 cell Panel)
22panels / hr
22 panels / hr
4800Wp / hour
4104 Wp / hour
38.400 Wp/shift
28.500 Wp/shift
115200 Wp/day (3 shift)
98.496 Wp/day (3 shift)
25 MWp/year
25 MWp/year
>25 MWp/year
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Productivity 32 panels / hr
>37 MWp/year
Manufacturing Lines Productivity PV Manufacturing Line to max capacity Line Description
Production/Year (3 shifts)
Number of Lines
Assembly line
25 MWp
1
Testing facility
> 37 MWp
1
Other machine: Glass washing machine Film cutter (EVA, Backsheet)
> 37 MWp
1
Ribbon cutter PUFIN POWER
PV Module technology PV Module has been designed in order to grant its performances during a long period of time: Raw materials and all basic components have been selected taking into account performances and stability. The full automatized process, the 100% power testing and the related product traceability allows to manage 25 years ensuring a predictable decreasing of targetted power (max 20%) The electrical interconnection of each PV Module has realized by fast insertion and water resistant MC connector
Micro-Prismatic temperated glass: low iron, 3,2mm as thickness and antireflection surface First layer of Etylene Vinil Acetate (EVA) film Poly Cells 156x156 mm made in Europe serial connected Second layer of Etylene Vinil Acetate (EVA) film Backsheet layer (PVF) Alluminum Frame: surface fixed to laminate by sealing tape
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PV Module Production cycle – PV Module and its components 1 Glass 6 junction box
2 EVA Film
3 Cells
4 EVA Film 7 Alluminum Frame
5 Polyester film
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Row Materials
Photovoltaic cells produced in Silicon Policrystalline
Backsheet = Multi-layer (polyester film contained between 2 film of weather-resistant material) Supplied in rolls of 100 Mt and width on demand EVA = Ethyl Vinyl Acetate Supplied in rolls of 100 Mt and width on demand Ribbon: Tape of copper coated outer by tin lead silver Supplied in rolls of 5 kg and length between 150 and 350 meters per Kg Available in standard lengths and cut according custom specifications; corners at 45 degrees Junction box: provided in version 3 diodes
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Production Cycle
Cells soldering
String Production
Panel LayUp
String Soldering
Sandwich Composition
The production process utilizes 2 Tabber & Stringer by Teamtechnik, laminators (Meier-Solar and Burkle) and one indipendent flasher by Berger Lichttechnik, the fully automatized lines grant the power measurement per each PV Module produced Sanwich Lamination
Edge trimming & Tape
Panel Framing & Sealing
Testing
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Pachaging
Shipment
PV Cell Tester (Incoming-Inspection) Supplier: PASAN (Switzerland) – CT606 The Equipment is installed in the reception area in order to execute the samplig incoming inspection, it is used in order to verify the Cells Conformity before the assembly. The Tester is able to verify fastly an irradiation non-destructive test upon the cells as well as the PV Cell performances and electric characteristic. The PV Cell testing allows to grant the quality of the main PV Module component. The equipment is thermically controlled realizing the STC conditions.
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Glass Washing Machine: Triulzi SP 1610
Supplier:TRIULZI (Italia)– Productivity: 3 glasses/min This equipment (20 installation World-Wide done in PV sector) allows to wash the glasse used in the PV Module manufacturing line. The washing uses demi water and the equipment is able to manage glasses up to 14mm as thickness and has been equipped by a very efficient drying system. The washing phase grants the best optical performance of the PV Module and prevents the possibility of contamination during the lamination.
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LayUp and Cell Soldering
N. 1 TT1200 (ELIFRANCE) –Capability: 1200 cicle/h
N. 2 TT900 (EL.ITAL.) – Capability: 900 cicle/h This equipment realizes the transport, the positioning and the soldering of PV Cells without any manually operation reducing consequently the OFE (Opportunity For Error) of the process.
This technology is currently used by the main PV Module German Producers while the rest of the other PV Module European Producers generally prefer to act the manual cells positioning and soldering and consequently is very high the risk of cell microcrack.
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LayUp and Cell Soldering (some details) CELL-AOI (Automatic Optical Inspection): each cell is optically tested before its use in the string
Cells resulting NOT OK (i.e. Irregular shape, silk printing defected or bad color) are rejected.
Infrared Soldering: the ribbon soldering process is realized by IR lamps without any contact
The mechanical stress due to soldering process is eliminated and consequently the possibility of microcracks Automatic LAYUP The handling of Cells is realized by High Precision Robot System able to act granting the minimum level of mechanical stress The positioning and the geometry are optimized and the precision got is impossible to get manually. Never the operator handles the cells.
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Reverse-Bias Test (Dark-Test) The test allows to verify the cells interconnections before the laminations. The test allows to check the electrical characteristics in reverse bias and in dark condition, The module has considered as passive component. In fact doing that it is possible to read the Series Resistance and the Shunt Resistance in order to detect eventual trouble before the lamination.
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Lamination Suppliers: MEIER-SOLAR and BUERKLE(Germania) – ICOLAM 38/24 e EASYLAM Productivity: 13 mod/h, equipped with double vacuum system , 24 zones controlled in temperature (+/-2°C)
The laminators made by Meier-Solar Solutions and Buerkle allow to realize the lamination process with the best quality level. The equipment have the capacity to laminate in high vaccum condition because they are using 2 pumps system. This feature is able to grant the absolute air absence within the laminate produced. The presence of air or other extraneous elements is able to reduce the life of the PV Module (lamination lost due to atmosphere and UV ray)
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Flash Test & Insulation Test
In order to deliver each PV Module produced with the its own performance certificate is has decided to use the Berger Lichttechnick Sun Simulator. The equipment is able to execute the insulation test too. The same equipement is utilized by test laboratory dedicated to the TUV PV Module qualification. The equipment includes the Xenon Lamp, the capacitor discharge banks, the controller, the fast ADC unit and the instrumentation to measure the insulation up to 5kV. The frame conductivuty has measured in order to certify the mechanical and electrical security. The test results are printed and attached to the PV Module. All the data are stored in the Information System in order to get the traceability of the products
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Module Series EL60
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Module Series EL72
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Mechanical drawings: EL Series
EL60
EL72 PUFIN POWER
Module Series EL60IS INNOVATIVE MODULE FOR TARGETED INTEGRATION ARCHITECTURE WITH FRAMES "CAPILLARY COMB" (PATENTED) The photovoltaic module EL.ITAL. with the frame "Capillary Comb" removes and replaces the use of conventional coatings cover and managed to achieve a coating architecturally integrated replacing the traditional robes of coverage. Colours of frame: aluminum gray, on request, other colors according to RAL color.
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Mechanical drawings : EL60IS
SECTION
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Glass MPT (Textured microprismatic)
Trensmitted light in a standard glass sheet
EL.ITAL. Poly-crystalline photovoltaic modules EL60, EL72, EL60/IS e EL72/IS series are built and optimized in order to maximize the module performance over the product lifetime. That’s why EL.ITAL. and ELIFRANCE adopted Micro-Prismatic textured glass for its modules; standard consumer products are equipped with a standard smooth glass sheet that, due to the refraction index difference between air and structured glass, causes a reflection on the incident rays of light. Surface texturing, can be used to minimise reflection in fact any "roughening" of the surface reduces reflection by increasing the chances of reflected light bouncing back onto the surface, rather than out to the surrounding air. The effect of the shadowing caused by the particles on the prismatic surface is strongly reduced due to the pyramids: in fact on the MPT glass the particles will fall just into the spires among the pyramids while on a standard glass the particles will distribute evenly across the sheet surface. Once again even in adverse conditions the MPT glass is profitable when compared to a standard smooth glass. The MPT feature grants a durable and optimised performance the the EL Modules in fact they can maximize the light energy available to the cells
Transmitted light in a standard glass sheett with dust particles evenly distributed on the surface
Trnasmitted light in a MPT glass sheet
Transmitted light in a MPT glass sheet with dust particles into spires between prisms
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Certificates MADE IN EU and AQPV
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Certificates MADE IN EU and AQPV
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Certification Safety-Health OHSAS 18001
EL.ITAL.
ELIFRANCE
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Product Certifications
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TUV Product Certifications EL.ITAL.
EL60 EL.ITAL.
EL72 EL.ITAL.
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EL60/IS EL.ITAL.
TUV Product Certifications ELIFRANCE
EL60 ELIFRANCE
EL72 ELIFRANCE
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PRODUCTS
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EMS Division
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Our EMS customers
E design partner: PUFIN POWER
EMS Division manufacturing lines
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Product Portfolio : Electronic Boards
Railway Energy Meter
Controller for GSM Base Station
PC Main-Boards
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Product Portfolio: PCBA
Controller Board and Power supply
Car Services Control Boards
IRIS-T Missile
Conditioning Controller Board
Welder Control Boards and Inverter
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Product Portfolio : Finished Product
Car services Control Device ADSL Home Welder
Access gateway
Conditioning Control Unit Railway Energy Meter
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(Nodi Porta)
Business Segments
5%
3%
15%
Industrial Defence Transportation Automotive
60% 17%
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Other
Tecnologies and Know -how
CABLES
PCB’S MANUFACTURING
FINAL ASSEMBLY
TLC SMD PROCESS (Inert environment & leadfree)
CONSUMER
MECHANIC
TESTING
METAL PARTS PLASTIC WORKSHOP MOULDING PAINT SHOP
AUTOMATIC TEST EQUIPMENTS:
ADSL ROUTER AOI, RX Control POWER METER
HW & FW ENGINEERING
•GSM BASE STATION •AUTOMOTIVE PROD. •POWER METER •MILITARY APPLIANCES
GSM BASE STATION SOLDER MACHINE FOR PTH PROCESS (Inert environment & leadfree)
AUTOMOTIVE
IN-CIRCUIT TESTER
ENVIRONMENTAL TESTING
CONFORMAL COATING
QUALITY AND ENVIRONMENTAL MANAGEMENT SYSTEM (ISO 9001 ISO TS16949 ISO 14001)
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1
Technical Know-how and production
2
Technical Know-how
PCBA manufacturing lines THT
SMD
Line 1
ATE (1)
(2)
Line 2 X-Ray
Line 3 AOI
Line 4
BURN-IN THT – Technology RX
SMD - Technology
Line Configuration
Machine Screenprinter Speedplacer Speedplacer Oven
Line 3: DEK 265 GSX 2 Siplace S25-S20 1 Siplace F4 Heller 1900W AOI S5 FLEX
Line 4: DEK 265 GSX 2 Siplace S20 1 Siplace F4 Heller 1900 ELX AOI S5 FLEX
Line 1: DEK Infinity 2 Siplace S25-S20 1 Siplace F5 Heller 1900 ELX
Line 2: DEK Infinity 2 Siplace S20 1 Siplace F5 Rehm 3800
420.000.000 CP/Y Capacity 1.050.000 PCB/Y (with 400 Comp/PCB) Technical Performances
SMD Comp. : Finest Pitch :
from 0402 up to 55 x 55 mm BGA,uBGA,QFP,COB 0.3 mm
Speed
64000 CP/h
Line 1: Wavesoldering machine TSM
Line 2: Wavesoldering machine Seho
ATE
(1) 2x Schlumberger Sprint S845 (2) 2x HP/Agilent 3070
Line 3: Wavesoldering machine Soltec
RX RX
5DX Agilent Bosello
Sn/Pb & leadfree solder bath Nitrogen (Inert environment)
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(1) In-circuit Test + Functional Test+ Open-Check Test, 2048 Testpins (2) In-circuit Test + Functional Test+ Boundary Scan + Test-jet, 5184 Hybrid Channels
EMS Division
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Quality System & Certifications
Off ISO / TS 16949 : 2009 - Automotive, 2013 ISO14001V2004 & OHSAS 18001V2007 by LRQA, 2012 EN 9100:2009, Aerospace Quality Management System, by L RQA, 2012 TS 16949 :2009 - Automotive EN 9100:2003, Aerospace Quality Management System, by L RQA, 2009 ISO 9001:2008 Quality Management System by LRQA, 2009 ISO14001:2004 Environment System by LRQA, October, 2006 Manufacturer of UL certified products, security for E-transaction
ISO 9001-2000 Quality Management System by LRQA, 2005 ISO 9002:1994 Quality Management System by LRQA, December, 1997
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Num of batch
Batch size breakdown
Lot size
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NPI & Mass Production Transition
Receive of BOM preliminary review data
Prototype builds P1
P2
Px
Final PCB Layout Re-spin Prototype
Pilot run (Pre Production Production run Quality)
NPI Team Production Team
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Revenue Breakdown in 2012 Oil Field
Energy
Industrial
Transportation
Aerospace & Defense
2011 (26.5M€)
Oil Field 5%
Industrial
Energy
29%
41%
Energy A&D Banking Industrial Oil Field
Banking 2%
A&D 23%
2012 (24.4M€) PUFIN POWER
Scope of Services Process: •
PCB layout Design
•
Industrialization (DFx)
•
Predictive PPM yield analysis
•
Assist Customer to qualify New Process, New technology
•
Prototyping
•
Printed Circuit Board Assembly Low Cost production
90 000 ppm
% DPU Fallout.
•
DPU Content Chart 100 000 ppm
80 000 ppm 70 000 ppm 60 000 ppm 50 000 ppm 40 000 ppm 30 000 ppm 20 000 ppm 10 000 ppm
Process
Specific process: Underfill, potting, High Melting Point HMP, Press fit, conformal coating,
soft lead, retinning
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Final Vis / OOBA
FCT#2 & Repair
Burn-in & Repair
FCT#1 & Repair
ICT & Repair
Advanced development of ICT and functional test
Manual Total
•
Total SMT Yield
Repair Center
Inspection Yield
•
Screen Print Inspection
Box Build
SMT ScreenPrint
•
SMT Placement
0 ppm
Assembly
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Final box cabling & assembly
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Specific process Press fit
Soft lead
Underfill
Potting
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Conformal coating
Retinning
THANK YOU !
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