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Solar Snake MaxTM
Messenger Wire
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Searching for answers in an unpredictable world
I attended the Intersolar & Energy Storage North America tradeshow in San Diego in late February — my first tradeshow since the second Trump administration took office. The mood in the exhibit hall was…subdued. Everyone claims to be busier than ever, but there is a hesitancy when looking toward 2026 and beyond. With increased federal support of fossil fuels, new tariffs initiated every day and executive orders threatening to roll back Inflation Reduction Act investments, it feels like we’re in an eternal limbo. The demand for solar is huge, but is there any support to build it?
Instead of discussing technology trends and new products, more people at the show wanted to thank the Solar Power World team for our everyday reporting. We’re all clamoring for shreds of accurate news in all aspects of daily life — not just solar. While I appreciate the kind comments about our editorial team just “doing our jobs,” it doesn’t exactly give me warm-fuzzies when thinking about the state of society. So know that our editors will continue to do the job that we have so much pride in, and we won’t report on anything until it’s vetted. I don’t want to preach too highly about ourselves, but we know that your work — installing panels, determining supply chains, developing policy — relies on Solar Power World’s dependable, trustworthy work. We have respect for you and for journalism, so we will keep doing our very best to bring you timely insights into all areas of solar and energy storage so we can actually look forward to the next few years.
We all need to hear it more often, so I’ll say it loudly: Thank YOU for keeping at it. Your work in solar might just feel like a job that pays the bills, but it’s important to so many lives. I’m very happy to be riding this rollercoaster with you all. Let’s continue to celebrate our wins this year.
kpickerel@wtwhmedia.com
Solar + sheep, supercharged
An inside look at lambing season at a Georgia agrivoltaic project
Safe harbor for solar
Safe harboring helps the solar industry lock in tax credits
Mounting Panels
Adjustments to solar racking products make space for farming
Silicon solar cell manufacturing returns to the United States
Inverters
Tax credit transferability brings upfront cash to manufacturers
Storage
New AD/CVD investigation impacts batteries
Special Section
Installation Tips
Leaders in the residential, C&I and utility-scale solar space share tips on how to make installation day as smooth and safe as possible. PAGE 33
Utility-scale solar contractors are constantly experimenting with new ways to make install days easier, from pre-building tracker rows to using robotic aids to help with the most strenuous tasks.
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Students visit a community solar array on a field trip organized by Nexamp. Nexamp
Operations
new project in their community; or digital marketing campaigns and informational videos.
"It's always education first," Clarke said. "We go into a lot of details that help the customer understand what it is; the benefits, [how] we're not a thirdparty energy supplier, why we're different, how it works. We spend a lot of time and effort and resources creating educational content to really help explain a program that can be somewhat challenging to understand. I mean, energy by itself is complex."
Nexamp develops, builds and maintains both the community solar arrays and the subscriptions, which Clarke said helps when starting one up in a new town. If it's successful, that array will be there for 30 years and will need subscribers for the duration.
"With new markets, new locales, you're starting from ground zero, because community solar is not on the national radar," said Keith Hevenor, communications manager at Nexamp. "It's really only on a state-by-state radar."
The company aids advocacy groups like the Solar Energy Industries Association and Coalition for Community Solar Access to raise awareness about the concept of community solar and how the programs work.
New York solar developer UGE does not manage community solar subscriptions but still found outreach a necessary element for project origination. UGE leases land for community solar projects, and landowners often require a similar education on the concept as potential subscribers.
Cece Carey-Snow, consultant for marketing and strategic projects at UGE, said people are aware of residential rooftop solar and large-scale utility solar, but community solar occupies a lesserknown space between the two.
"Explaining this middle-sized project that exists, but also the shared subscription model and the leasing of property to host a solar project is new to most people that we reach out to," she said. "Even in more mature markets like New York City and New Jersey, where we do a lot of work, there's still not a ton of awareness."
For potential project site owners, UGE has organized educational sessions across states permitting community solar, including a public series with the University of Maryland Extension that was a collaboration with other solar developers. UGE also publishes blog posts and builds paid marketing campaigns on the topic of community solar and its benefits for landowners.
“The paid marketing is education in large part, and especially because most people who see our messaging, whether it’s paid or organic, are not going to have a site that’s ultimately going to work for us,” Carey-Snow said. "The funnel is going to be so small … But at least these people know that this exists.”
Once land has been secured for a community solar project, UGE’s development team continues to
Nexamp conducts a public meeting on the topic of community solar. Marketing and educational initiatives like these are necessary elements of community solar development. Nexamp
educate the landowner, neighbors, town and community to dispel any lingering misconceptions of solar.
While community solar outreach can be cumbersome, UGE has found that education combined with a successful first project in a new town has led to more projects in those regions, Carey-Snow said. Gaining a foothold somewhere establishes the concept of community solar for these markets, which opens the door to potential developments in neighboring towns.
"It's funny. A lot of folks are like, 'Well, this seems a little too good to be true. So, you're going to pay me for leasing my land, and I save on energy, and so do my neighbors?’” she said. “It's convincing them that it's real and building trust and credibility." SPW
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PERMANENT SHEEP FLOCK
LEAVES GEORGIA SOLAR PROJECT’S LAND HEALTHIER THAN BEFORE
BILLY LUDT SENIOR EDITOR
Lambs born at the Houston Solar Project site live in the barn with their mother ewes and other sheep from their flock before grazing full-time underneath the solar array.
Kelsey Misbrener/Solar Power World
Installation
The ambitions of the Houston Solar Project predate the existence of Silicon Ranch, the Southeast solar developer responsible for bringing the 68-MW array to Perry, Georgia. A flock of sheep graze beneath the tracking solar module rows covering 697 acres off Firetower Road in south Houston County, a breed of ewes that over two decades has adapted to the environmental conditions of the region.
Developing that tolerance to the Southeast’s hot, wet weather started with Roxanne Newton, a consultant for Silicon Ranch and its land management subsidiary Regenerative Energy, who 20 years prior bought a small flock of sheep to graze her land. She quickly discovered that her sheep were vulnerable to native parasites, and she transitioned from being a hobbyist shepherd to tracking and logging her flock’s gene data to breed a stock of sheep capable of surviving in this climate.
“We worry that all the work I did over 20 years will be thrown away,” Newton said. “I hope that Silicon Ranch can pick up where I left off.”
Jim Malooley, director of agrivoltaics operations at Silicon Ranch, said Newton is the single most impactful person for sheep genetics in the Southeast. Malooley is also a first-generation sheep farmer and was mentored by Newton.
“[Parasites] are a threat to any species,” he said. “The biggest killer of sheep in this country isn’t wolves or bobcats — it’s a parasite.”
Their efforts in sheep breeding have culminated in the Houston Solar Project, the first within Silicon Ranch’s portfolio that has on-site facilities for guiding sheep through their full lifecycle.
An open-air fabric barn hosts 16 pens housing up to 400 birthing ewes and lambs just outside the boundary fence of the solar array. While Solar Power World was visiting the site, we witnessed one birth. Several minutes after the lamb was born, it was upright and walking. The lamb will reside for a short time with its mother, other sheep and guardian dogs, socializing in the pen before living and grazing full-time beneath the solar array.
Houston Solar is built on both sides of Firetower Road, so the flock is routinely transferred from one side of the street to
Installation
the other or guided from one section of the array to another for planned grazing. Agrivoltaic technicians, the shepherds keeping this flock, maintain a database of every sheep at Houston, connecting the newborn lamb to the ram that sired it and ewe that birthed it.
Operations there are a combination of modern practices matched with ageold customs.
“Shepherds and herding dogs have worked together forever, and we still do,” Malooley said.
The sheep are responsible for landscaping all 697 acres of the Houston Solar Project. In 2024, the agrivoltaics technicians didn’t need to mow the bulk of the land for the first time — only some minor cleanup around the perimeter. Instead, it was managed entirely by the sheep themselves over five planned grazes.
By using sheep instead of landscaping equipment, Silicon Ranch is naturally improving the health of the soil beneath the solar array and avoiding the use of chemical fertilizers and fossil fuels. Sheep manure acts as a natural fertilizer that increases the microbial activities in
the soil, leaving it healthier than before. This process also boosts the land’s biodiversity, drawing more local wildlife to the site. But there’s still much to learn about soil health and how the flock is remediating it.
“We’re embracing the unknowns in the soil and the forages,” Malooley said. “It turns out that there are some rhythms in the chaos.”
Regenerative Energy was started to implement holistic land management practices on Silicon Ranch solar project sites. Houston Solar’s land was originally zoned for subdivisions. Instead, those nearly 700 acres retain a topsoil that will remain undisturbed by any other developments for the remainder of the solar project’s operating lifespan. Keeping the topsoil intact helps with water retention, preventing runoff from precipitation.
“It really was a revelation for us. We are owners of our land. As landowners, we have a responsibility to be good stewards of the land,” said Matt Beasley, chief commercial officer of Silicon Ranch.
The array is composed of Nextracker NX Horizon-XTR single-axis solar trackers
built at “sheep height,” with a leading edge of 24 in., so the flock can’t reach the First Solar panels above. There is additional spacing between tracker rows to accommodate farm equipment that can transport sheep or unfurl bales of hay for supplementary feed when the grass is dormant.
Flint Energies, a regional electric cooperative and member of Green Power EMC, entered a 15-MW power purchase agreement with Houston Solar.
“This right here is an important part of our power supply,” said Jeremy Nelms, CEO of Flint Energies.
The sprawling array abuts Interstate-75, and an electronic billboard erected next to the lambing barn conveys its accolades to commuters passing by. Silicon Ranch deploys sheep flocks on 25 of its solar projects, but Houston Solar’s setup isn’t something that can be repeated at every array it owns.
Houston Solar wouldn’t operate this way without the unique efforts of farmers in the Southeast. Sheep were once popular livestock among farms in the region, but the population has dwindled over the last century.
Nigel the sheepdog trots beneath the Houston Solar Project in Perry, Georgia. Guardian and sheepdogs assist shepherds with raising and corralling the sheep here.
Kelsey Misbrener/Solar Power World
Malooley said Houston Solar is an example of how a solar project can provide parallel benefits of both energy and food security. He said this isn’t something Silicon Ranch can replicate at every project, because decades of work made it possible. Instead, the goal is to recognize the individual needs of each project and find new intersections between agriculture and energy production. SPW
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Solar projects 1 MW and larger that qualify for the investment tax credit (ITC) or production tax credit (PTC) and accompanying Inflation Reduction Act bonus credits aren't finished overnight. Timelines for securing financing, completing design and permitting and actually installing a project are a measure of years, not days. Financiers looking to invest in IRA solar projects need the certainty that the tax credits will materialize and provide a solid return on investment. The "safe harbor" provision makes this possible.
Safe harboring allows companies to demonstrate a good-faith effort at starting a solar project to lock in the applicable tax credits in place that year. Once they secure the credits, they have four years to complete the project — known as the “continuity safe harbor.”
For the ITC or PTC, companies can safe harbor the credits two ways — either by physically starting the project or incurring 5% of the cost of materials for the project. The former method, often called the "physical work test," applies
either to onsite work or fabrication of custom equipment for the project offsite. Keith Martin, partner at law firm Norton Rose Fulbright, said utility contractors typically must start work on the site's main power transformer to qualify.
For the 5% test, companies need to do more than just pay for equipment — those products must be delivered to them, and thus installed or stored, Martin said.
Safe harboring looks different for residential solar contractors than for utilityscale contractors. Residential contractors can claim these bonus credits for thirdparty owned systems, and will typically stockpile inverters or solar panels to secure the safe harbor.
"They don't know when they're stockpiling where the equipment will be used, but they use enough stockpiled equipment to get above 5%," Martin said. "It's been a little more careful for utilityscale [contractors] to have at least some idea where the equipment will be used when you're buying it."
The national residential installers most likely to take advantage of the IRA’s
domestic content credits must think through some considerations before deciding which products to choose for safe-harbor. First, they need to ensure they have warehouse space to physically store those products. Next, they must choose a technology that will remain upto-date over the four years they have to install the products.
Many of the major manufacturers with operations in the United States have announced safe harbor "partnerships" with national installers and financiers. SolarEdge announced such a partnership with Sunrun, and Enphase joined with IGS Solar.
Raghu Belur, chief product officer at Enphase, believes microinverters are a good safe harbor choice for their small size and remote updates. Whereas solar panel advancements happen quickly, microinverters operate on longer technological timelines.
"Because we are completely software-defined, there's very little risk of any technology obsolescence," Belur said.
Whether companies opt to start physical work or pay for 5% of the cost of materials, they must continuously work on the applicable project and finish it within four years.
"Both of those methods require the developer to make continuous progress on the construction of the project, and in the four-year continuity safe harbor requirement, to make sure that it's built within a reasonable window after the construction begins," said Lesley Hunter, SVP of policy and engagement at the American Council on Renewable Energy (ACORE).
Safe harbor outlook in 2025
Contractors rushed to lock in the safe harbor by the end of 2024 to take advantage of the current ITC bonus credits — including the 10% domestic content credit and energy community credit. The required percentages of
domestic content needed to claim the credit are set to rise from the initial 40% by 5% every year until it holds at 55%, making it harder to secure every year. If owners are seeking the energy community bonus credit, a project could potentially fall in and out of that designation over the years depending on changes to the unemployment rate and fossil fuel-related tax revenues used to achieve the designation.
Companies were also eager to lock in current credits before any potential IRA changes under the new Trump administration, which have already been thrown into question after a series of executive orders.
"The reason to start construction last year is it's hard to see how a new Congress in 2025 can disturb an option people had under the 2024 tax code to claim tax credits," Martin said. "But now that we're in 2025, everybody's
under these new tax code sections, and the Republican Congress is likely to either accelerate the phaseout of these tax credits under the new sections, or there has been talk about reducing the amount but allowing a higher tax credit if there's enough domestic content."
Contractors that were not ready to start construction last year are now racing to do so before early spring, when the House of Representatives Committee on Ways and Means is likely to begin reassessing the Inflation Reduction Act.
"Anybody who starts construction before the tax bill starts moving, historically, has been grandfathered from the change as long as the project is completed within a certain period of time. So there are people who are still rushing to start construction early this year," Martin said. SPW
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Solar Spotlight: An introduction to string sizing optimization with Sungrow
On this episode of Solar Spotlight, Benjamin Heitmann, marketing manager, and Madeline Acri, applications engineer with Sungrow North America discuss the company’s history of manufacturing solar inverter technologies and dive into some of the specific features of string inverters.
A written portion of this podcast is below but be sure to listen to the full episode on your preferred podcast service.
SPW: What is Sungrow's company mission?
Benjamin Heitmann: Sungrow’s mission is simple, yet powerful, and that's to provide clean power for all. Sungrow USA Corp. is a leading provider of renewable energy solutions, specializing in the development and manufacturing of photovoltaic inverters and energy storage systems as a subsidiary of Sungrow Power Supply Co., a global leader in the renewable energy industry. Sungrow USA is dedicated to driving the growth of clean power in the United States. We offer a comprehensive range of products and services designed to optimize the performance and efficiency of solar power installations.
Can you provide some background on solar inverters and specifically string sizing?
Madeline Acri: An inverter is a device that converts direct current electricity to alternating current, and Sungrow makes solar inverters, which convert DC power from solar modules to AC power that feeds the utility grid. The energy in PV inverters only flows one direction from DC to AC. Sungrow also has the energy storage division, which manufactures power conversion systems, also known as PCS, which is a bidirectional converter. PCS can convert DC from a battery, or solar source, to AC from the grid, and it can also take the AC grid power as an input to charge the battery.
orientation, and the quantity of modules inputted into a solar PV inverter.
Can different types of modules be installed on a single inverter?
MA: Well, the short answer is it depends. For each inverter, there are different design parameters for the DC PV inputs. The PV side is what you would be evaluating to determine how many different modules you may be able to use. There are physical connection points on the inverter where the positive and negative wiring runs will plug into the inverter. Some inverters have only a single DC input, but other inverters could, for example, have up to 24 DC inputs. Depending on the style of the inverter, you may have more or less flexibility on module type based on the PV input connections and MPPTs.
What happens if a PV string voltage exceeds 1000 V?
MA: The 1,000 VDC design limitation is really dependent on the inverter type. But for our rooftop inverters, let's specifically say the SG36CX-US, and the SG60CX-US, 1000 V is our maximum DC voltage operating range. If we exceed this value, the inverter will experience a fault. It will say “PV input mode error,”
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When we talk about string sizing, we're going to consider module selection, array
and the inverter knows to shut down and disconnect. Then it will try to reconnect again once it senses that this input voltage has lowered and is within the operating range.
So, that's something to consider if you're working on a rooftop in North America. Typically, the limitation is 1,000 VDC, if you're in a commercial setting, and with a ground mount, that level is 1,500 VDC. You want to consider your site when you consider how many modules to connect in series, because that string length is measured based on those different codes. The inverter is smart enough to know that if the PV string voltage does exceed the operating threshold, the inverter will shut down. SPW
Benjamin Heitmann Marketing Manager Sungrow North America
Madeline Acri Applications Engineer Sungrow North America
A cow rests beneath a solar project developed by BlueWave. By elevating solar arrays and granting more space between module rows, it’s possible to pair solar and agriculture on the same plot. BlueWave
SOLAR RACKING MAKES AGRIVOLTAIC PROJECTS POSSIBLE
BILLY LUDT SENIOR EDITOR
The American solar industry is testing the viability of co-locating solar PV and agriculture on the same plots, and the solar racking used on these projects makes that possible.
Pairing solar projects and agriculture isn’t yet an exact science, but no matter the activity happening below or near a PV array — if that’s tending to livestock, cultivating crops or maintaining pollinators — it often requires taller racking and more space between
module rows. This combination of solar and farming is a form of dual-use photovoltaics, also known as agrisolar or agrivoltaics.
According to the 2022 Census of Agriculture, the United States had more than 1.9 million farms tending to 880 million acres of farmland. While this still accounts for millions of square miles of land, American farmland has decreased by nearly 75 million acres since 1997, according to census reporting. Most of
that lost farmland is pastureland used for livestock, and tracks with a policy change allowing farmers to grow animals in confinement, according to an analysis published by farmdocdaily
“Farmers are very receptive to the idea of agrivoltaics but very hesitant to take on projects with risk,” said Ian Skor, owner and CEO of Sandbox Solar, a solar contractor in Fort Collins, Colorado, that is championing agrivoltaics. “Minor changes to their
Mounting Technology
farming practice can have a big impact. They’re already operating on slim margins.”
Solar is pitched as a lifeline to farmers, a steady source of income that can help keep farmland in the family. Proving agricultural activity can continue within the borders of solar arrays can have a greater economic impact than choosing one or the other.
Agrivoltaic solar racking
Making solar racking suitable for agrivoltaic projects mostly means elevating it on higher posts to grant enough headroom for whatever happens beneath the modules. Extending the height of an array increases the impact of wind and other environmental conditions and requires additional engineering to ensure it can withstand the extra pressures. If a solar array is also sharing land with active farm equipment or livestock, especially cattle, then it must be built to handle possible collision too.
"By our earlier design decisions, we became inherently cow-proof — or buffalo-proof,” said Travis Jordan, CEO of MT Solar, a solar racking manufacturer from Montana. "Even large-scale ag equipment, we can handle some light rough-housing. If a planter got thrown off and bashed into a post, it's not going to hurt anything."
MT Solar produces top-of-polemounted solar racking for agrivoltaic projects with a design informed by Jordan’s upbringing on an off-grid homestead. This pole mount was made to minimize construction activity by using a single ground-mounting point while still accommodating uneven terrains like Montana’s rising hills and mountains. The module table can be manually rotated to follow the sun’s course throughout the year and, for agrivoltaic purposes, adjusted to make room for farm equipment or planned shading.
Helge Biernath, CEO of solar contractor Sunstall and vertical racking manufacturer Sunzaun, said shade is a valuable resource as many crops, like root vegetables and leafy greens, only need a few hours of sunlight a day to
The racking used on this array is manufactured by MT Solar, and can adjust to accommodate livestock, crops or farm equipment on the site. MT Solar
Polar Racking produces a single-axis solar tracker that can be modeled for agrivoltaic purposes.
Mounting Technology
grow; and agricultural workers value the shade when working in the sun for prolonged periods.
Sunzaun is a solar fencing product with a smaller project footprint than other ground-mount racking. While it doesn’t have the same generating capacity as a single-axis solar tracker, it can fit into narrower tracts and still produce electricity.
"You can actually gain something out of it, and your wood fence is not going to pay you back anything," Biernath said. "Yes, the CapEx is going to be high in comparison, but there is going to be money coming in on the other end, and that's the difference."
Polar Racking, a solar racking manufacturer from Ontario, Canada, has designed three of its ground-mounts to work on dual-use projects. Each model — vertical fencing, fixed-tilt east-west canopy and single-axis tracker — are designed to minimize construction impact on these agricultural sites by reducing the number of piles necessary and preassembling components off-site.
Sam Alradhi, VP of operations at Polar Racking, said the goal is to not disrupt operations or damage a farmer's soil, "because the soil is everything." Additionally, the tracker and fixed-tilt models are elevated so livestock, farm equipment and produce can thrive underneath. Polar Racking has even modeled racking with feed trays so farm animals could eat in the shade of an array.
"It's time that we utilize the land even more efficiently by again having our livestock or crops or whatever while
Polar Racking
Mounting Technology
producing solar. We don't have to choose one over the other anymore. We can coexist," Alradhi said.
Stracker, a dual-axis solar tracker manufacturer from Oregon, initially designed its tracker with dual purposes in mind. These systems have been deployed in pilot agrivoltaic projects with universities and more commonly on car dealership lots. Jeff Sharpe, founder and COO of Stracker, spent 10 years farming a 50-acre plot in Montana and eight years designing a tracker to install over farmland.
“As we were designing and coming up with this tracker project, we saw the real value to the agricultural market, being able to have combines go under the equipment,” he said.
Making agrivoltaics work
Pairing a solar array and crops on the same plot increases the economic value of that single tract more than if the technology and crops were separated. It's likely that the solar array will not
have as large of a power density as a solar project without agriculture, but yields of both crops and electrons will be more profitable than a plot with only one or the other.
Trade organization SolarPower Europe published the “Agrisolar Handbook” in 2024 as a resource for European farmers and solar developers, with the goal of making dual-use projects "benefit the farmer, the solar stakeholders, investors and the local community."
American farmers and solar companies can take notes from the handbook, as both the European and American agricultural industries are facing similar hurdles of land constraints, income uncertainties and a changing climate resulting in water scarcity. Agrivoltaic projects have the potential to increase yields for certain varieties of shade crops, increase water retention, maintain soil temperatures, assist with carbon sequestration in soils and increase pollinator activities,
according to the handbook.
BlueWave, a solar developer from Boston, has a department dedicated to dual-use solar projects. Jesse Robertson-DuBois, is director of sustainable solar development at BlueWave and a farmer based in Western Massachusetts.
"I came to solar with the perspective that farmers are pretty innovative folks that figure out how to grow products or raise livestock in a lot of different places, and there’s none of this that’s that hard,” he said. “Solar development is hard. Farming is hard. The places where you can overlap them — it doesn’t take a magic wand — it just takes looking for the places and the people that have good overlap.”
Solar racking manufacturers are poised to fit the needs of the agricultural community as early agrivoltaic projects test the legitimacy of the pairing. The grid is electrifying, as is farming, and on-site solar is there to help both sides. SPW
Stracker Solar recently deployed its dualaxis trackers at Our Table Cooperative, a 58-acre farm in Sherwood, Oregon. Oregon Clean Power Cooperative
Kelly Pickerel • Editor in Chief
Silicon cell manufacturing restarts in America
A mere 10 years ago, all of the core components of the silicon solar panel supply chain could be found in the United States. A visit to SolarWorld’s 530-MW factory in Oregon — the largest such factory in the Western Hemisphere in the early 2010s — had ingots, wafers, cells and panels coming off its lines. Across the country in Georgia, Suniva was making around 400 MW of cells at the same time. With only a smattering of other solar panel assembly facilities in the United States in 2015, these two companies could easily meet the country’s need for “domestic content” before that phrase was even in our lexicon.
But the landscape quickly changed. Antidumping investigations and a trade war with China led to Suniva and SolarWorld closing their doors in 2017 and 2018, respectively. There have been no ingots, wafers or cells made in America since.
The United States today has enough silicon solar panel assemblers to meet the country’s demand for solar modules, but the upstream components are still lacking. The situation is slowly changing though, and 2025 will likely be recognized as the turning point in American solar manufacturing.
Miraculously, at the very end of 2024, Suniva started making solar cells again after seven years of dormancy. The company’s 1-GW annual manufacturing capacity is a drop in the bucket for the country’s 50-GW panel production potential, but a start is a start. Now a second name enters the wide silicon cell manufacturing pool — ES Foundry just opened a 3-GW silicon cell factory in Greenwood, South Carolina. Solar Power World got to take a look inside.
SPW visits ES Foundry
The most noticeable characteristic of the ES Foundry building is the scale — the 400,000-ft2 factory feels massive with gas offtakes coming off its sides. The “foundry” is in a former building used by
Fujifilm to make inkjet paper and other photo products. CEO Alex Zhu said that the height of the Fujifilm building is what first attracted him to the space, as there aren’t many existing 70-ft-tall manufacturing sites in America. Fujifilm occupied five stories of the building; ES Foundry knocked out four stories to make one large open space to fit chemical piping and manufacturing equipment. The building’s height could also accommodate silicon ingot pulling and wafering in the future, if it makes financial sense, Zhu said. It would be unique to have a site ready to go and not have to rely on a whole new build.
The difference between a panel assembler and a cell manufacturer is apparent at once. Solar panel manufacturers are assembling cells, backsheets, junction boxes and frames. Cell manufacturers are more chemicalfocused and rely on clean operations.
A look back at SolarWorld’s production site in 2009, the last time there was an inclusive wafer-cell-panel manufacturing facility in the United States. Oregon Dept. of Transportation
Before entering the plant, workers (and visitors) must don head-to-toe protective gear and walk through an air bath to remove airborne contaminants. Zhu said ES Foundry is able to source most of the chemicals used in manufacturing — phosphorus, silicon nitrate — in the United States, while, of course, the wafers, silver paste and aluminum paste are coming from Southeast Asia for now.
Besides finding a building that was the right height and equipped with proper electricity and wastewater hookups, ES Foundry was fortunate the local Greenwood workforce was already familiar with chemical processing. Ascend, a nylon polymer and fiber manufacturer just down the street, recently announced it was shuttering. ES Foundry has already hired many former Ascend employees and is holding more job fairs locally. Construction on ES Foundry’s interior took just eight months, and 125 workers are now on the
payroll. The company expects to have 300 employees by the end of March and 500 by Q3, which would make ES Foundry one of the largest employers in Greenwood.
ES Foundry is making bifacial PERC cells in South Carolina, a logical choice to avoid the unpredictable future of TOPCon panel production in the United States. The cells first start as gray silicon wafers and go through many steps on their seven-hour journey to finished product, including diffusion, etching, oxidation, back passivation, plasma enhanced chemical vapor disposition and screen printing. The “diffusion” step is likely the most important, as that is when the dope paths (p- and n-type processes) are established. Only when the diffusion step
is done on American soil can a solar cell be considered domestic-made and qualify for any domestic content advantages. This should be the year for more solar cell manufacturers to come online in the United States, providing Americanmade cells to projects pursuing domestic content. Qcells is close to opening its wafer-cell-panel operations in Georgia
and Silfab is still hoping to begin cell manufacturing in South Carolina. Other companies like Boviet Solar (North Carolina) and Canadian Solar (Indiana) could begin silicon cell operations within the next 18 months. They will join Suniva and ES Foundry in the revitalization of the U.S. solar manufacturing industry — and not a minute too soon. SPW
Inside ES Foundry’s silicon solar cell manufacturing operations in Greenwood, South Carolina.
Kelly Pickerel/Solar Power World
Kelsey Misbrener • Managing Editor
45X tax credit transfers strengthen US solar manufacturing
The Inflation Reduction Act’s tax credit transferability provision has helped difficult solar projects get financed and given more entities the chance to invest in solar. Transferability is now also helping solar manufacturers build their stateside operations by maximizing 45X manufacturing credits.
The 45X Advanced Manufacturing Production Credit is offered to domestic manufacturers of eligible solar and storage components, such as panels, trackers, inverters and batteries. Barring any change to the tax code, full credits are available through December 31, 2029, after which a phasedown begins.
The upfront costs of building out domestic solar manufacturing can be daunting. The 45X credit helps make it possible, whether companies choose to
wait until tax season to use it or get cash upfront through the transferability market.
"These are companies that are needing to get loans to build out their manufacturing facilities. If you can include the sale of these 45X credits in the cash flows of that solar panel manufacturer or lithium mining extraction technology, you're helping their economic case in terms of being able to grow a business that takes significant upfront capital," said Erik Underwood, co-founder and CEO of renewable energy tax credit marketplace Basis Climate.
Basis Climate is one of a handful of renewable energy-specific tax credit marketplaces formed after the IRA made transferability an option. These marketplaces take a small cut of the transaction to handle all behind-the-
scenes work to transfer tax credits to a company or individual looking to reduce their tax liability. Credits are sold at a discount on the dollar to make it worthwhile for buyers, while giving the sellers more liquidity in the short-term.
Canadian solar panel manufacturer Heliene is just one company that has used 45X credit sale proceeds as collateral on a loan to finance the company's working capital.
"Even if you need to discount a few pennies on the dollar, what you're selling is always a better deal than paying interest on your money for a year and a half," said Martin Pochtaruk, CEO of Heliene.
Heliene sold its 2023 and 2024 45X credits for $50 million to an undisclosed company and is now seeking buyers for its 2025 credits.
SolarEdge workers at the company’s manufacturing plant in Austin, Texas.
SolarEdge has used 45X tax credit transfers to pull cash forward and reinvest in U.S. inverters. SolarEdge
"The buyer for our 2023 and 2024 credits is an Ohio-based company that has hundreds of millions in tax liability. It is the first time they were buying 45X, while they've been buying PTCs and ITCs for a long time," Pochtaruk said.
Inverter manufacturer SolarEdge is another company that sold its 2024 45X credits for $40 million. J.B. Lowe, head of SolarEdge investor relations, said 45X credit transfers are another way to cut corporate taxes. "It gives tax-paying corporations the ability to offset tax liabilities. It's interesting, in a way, that the Trump administration wants to extend a bunch of tax cuts. This type of mechanism helps corporations lower their taxes," Lowe said.
SolarEdge also sees an advantage in selling these discounted credits ahead of time to pump more money into operations in the near-term.
"We're a public company, and we have expenses all the time. Anytime you can get cash sooner, if you could do it in a cost-advantageous way or price-advantageous way, then it's something to consider. It's all about time, value of money and whether it's worth the transaction costs and discounts to pull that cash forward rather than waiting," Lowe said.
“This is the IRA delivering on its intent, which is to incentivize highvalue domestic manufacturing by providing manufacturers with the liquidity they need to reinvest in growth and innovation”
— Mark Widmar • First Solar
While Heliene and SolarEdge profited in the tens of millions of dollars from 45X sales, U.S. thin-film solar panel manufacturer First Solar facilitated the largest publicized 45X transfer sale thus far. The company sold $700 million of its credits to financial services company Fiserv for 96¢ per $1 of tax credits.
“This is the IRA delivering on its intent, which is to incentivize high-value domestic manufacturing by providing manufacturers with the liquidity they need to reinvest in growth and innovation,” said Mark Widmar, CEO of First Solar, in a press statement. “This agreement establishes an important precedent for the solar industry, confirming the marketability and value of advanced manufacturing production tax credits.”
While the companies selling 45X credits are motivated to lower their loan amounts and increase current cash on hand, those buying the credits are
Inverter Technology
bolstering U.S. renewable energy manufacturing. Electronics manufacturer Schneider Electric, which makes numerous products for the residential solar market including inverters and smart meters, purchased an undisclosed amount of 45X credits from Silfab in 2024.
"45X, really, is a jobs story. It's another way to support the downstream needs of the solar industry. We all believe in 'Made in America,' and we all believe in American jobs. And so how can we stand in that space and support that in order to help our clients believe in it too?" said Emily Rose, associate director of renewable energy investments at Schneider. "Schneider, I don't think, would have bought [just] any tax credit. They really wanted to stay within the overarching sustainability culture that they live and breathe here."
In addition to mission-driven investing, purchasing production-based tax credits like 45X also comes with less risk than investment-based credits.
"We've talked to plenty of buyers that say, 'I want to support 45X credits because I like the risk profile of a production-based credit, but I also like the story of diversifying and supporting American clean energy manufacturing,'" said Basis Climate’s Underwood.
The fate of many IRA elements, including 45X, is up in the air with the new oil-and-gas-centric Trump presidency. Some members of Congress are seeking to block the 45X manufacturing credit from companies with ties to China, a task that could complicate this credit moving forward. But Schneider's Rose believes there's no immediate threat.
"I don't know why transferability specifically would be taken away when it is the most free-market part of tax credits. 45X, which helps support job growth and keep the downstream supply chain within the United States, seems to me to be a really nice, protected space," she said.
Even if laws were to change, tax transfer contracts through Basis Climate and other platforms have change-inlaw clauses that allow parties to unwind transactions. Underwood believes buyers should feel comfortable purchasing tax credits this year and even begin to make plans for 2026.
"We think that buyers acting right now, who have the ability to strategize their taxes and have the ability to make commitments, should be ready to go, and they should feel comfortable doing so," Underwood said. SPW
Kelly Pickerel • Editor in Chief
Battery anode materials AD/CVD worries energy storage and EV market
A new antidumping/countervailing duties (AD/CVD) investigation could affect domestic manufacturing and deployment of lithium-ion energy storage and EV batteries in the United States.
A group of domestic anode material startups calling itself the American Active Anode Material Producers (AAAMP) filed petitions with the Dept. of Commerce and U.S. International Trade Commission in late 2024 seeking AD/CVD on imports of battery anode material from China. AAAMP says China’s dominance on active anode materials (AAM) production
has prohibited the domestic market from establishing competitive operations.
The ITC agreed with AAAMP, stating in January that the U.S. AAM industry has been “materially retarded” by dumped and subsidized imports from China. The ITC’s positive preliminary decision uniquely lets other domestic material startups allege material retardation. Previous AD/CVD cases regarding solar panels proved levels of harm to the domestic market on a clear “before” and “after” basis, but the AAM industry does not have adequate product output to make this comparison. Tariffs on imported active anode materials could help the domestic AAM industry actually get off the ground, the group claims.
The Dept. of Commerce is expected to reveal its preliminary CVD decision in March and its preliminary AD decision in May. Nothing would become official until final decisions are released between July and September.
What are active anode materials?
A battery needs both a cathode and anode to facilitate the flow of electric charge. During battery charging, electrons move from the positive cathode to the negative anode, and that electrical difference is what translates to stored energy. The stated “chemistry” of a battery is its active cathode materials — lithium iron phosphate (LFP) or lithium nickel manganese cobalt (NMC), for example. Active anode materials are typically carbon-based — like graphite powder or silicon oxide. AAM are mined, ground to a fine powder and then coated on the anode (usually copper foil).
While the United States does produce graphite materials, it does not significantly produce the type of graphite used in active anode materials, which requires a specific particle size, density and purity. The AAAMP is requesting duties on Chinese AAM with at least a 90% purity level, although the group is ultimately targeting AAM used in EV and ESS products.
Storage Technology
Those involved in early steps of the battery supply chain sign long-term offtake agreements with AAM producers and perform ongoing purity testing of the material. Tesla stated in court documents that it only uses AAM with 99.9% purity in its battery products, and no domestic AAM producers are currently able to hit that number.
Who would be most affected by tariffed AAM?
While Tesla did state in court documents that it tests AAM purity, it’s unclear which battery component producer imports the graphite materials. Most “battery manufacturers” or “energy storage system providers” in the United States do not
have a say in AAM used. Battery cell manufacturers may import anodes with AAM already coated, and ESS providers usually are just concerned about battery module racks in enclosures.
The duties requested by AAAMP are broad — especially since they could be levied against anode materials imported separately, in a compound or in a finished battery. Synthetic or natural AAM could be tariffed in powder, dry or liquid form. The petitioners have requested duties over 900%, which would significantly increase the price of a battery — estimates range from $28 to $135/kWh. For a 5-MWh energy storage container, even just a $40/ kWh tariff would add $200,000 to the system’s cost.
Additionally, some imported Chinese AAM is already tariffed under Sec. 301 and other blanket Chinese tariffs initiated by President Donald Trump. The AAAMP asked for a deeper look at AAM used in EV and ESS, with most focus turned to the EV market specifically. It is likely that Commerce would establish a range of tariff percentages for different product types, so how this would affect lithium ESS deployments in the future is anyone’s guess. SPW
Solar Power World will report on the decisions made by the Dept. of Commerce and ITC on our website: solarpowerworldonline.com.
TIPS
SOLAR INSTALLATION TIPS
RESIDENTIAL
INSTALLATION TIPS
ROOF FOR THE FIRST TIME?
Safety first, second and third! Going home to your family at the end of every day is more valuable than rushing to get a job done. We have a saying — "Slow down to speed up." If you're going too fast, you're more likely to make a mistake and have to do it all over again, which will take twice as long as when you could have done it slow and steady and properly the first time through.
Jordan
Gietz, President, Energy Service Partners (ESP)
Safety is our top priority, so before we allow anyone on a roof, we make sure they fully understand our safety standards and ensure they have the correct equipment for the job. This includes how to use and check all of their PPE, how to order replacements in the future and how to provide regular checks to the field operations team. We’d also stress the importance of making sure their fall protection gear is properly secured. We’d remind them to use three points of contact when climbing, to keep their tools secure and to communicate clearly with their team. Lastly, we'd remind them to stay aware of their surroundings and if they're unsure about anything, ask for help.
Tanya Hall, COO, eEquals
INCLEMENT WEATHER CONDITIONS?
Back to safety, we have a tight threshold for keeping our people out of harm's way if there's going to be rain that leaks to slick surfaces or other weather that creates unsafe working conditions. We know it can lead to disappointed customers who have to wait for another day to get their job finished up, but more often than not people are very understanding and don't want to put anyone at risk for the sake of speed.
Jordan Gietz
eEquals takes pride in outfitting our crews for any weather condition. In our market, we deal with both extremely cold and hot weather. In the winter, our cold weather kits include snow torches, de-icers, body warmers and company-issued coats. In the summer months, we provide water, hard hat visors, moisturewicking shirts, and cool wraps. Overall, we constantly monitor the weather conditions to ensure we are not putting our crews in unsafe environments.
Tanya Hall
WHAT IS THE HARDEST THING ABOUT RESIDENTIAL SOLAR INSTALLATION? WHAT IS THE EASIEST?
The hardest thing is that every single homeowner is different, every home is unique and there's no such thing as one-size-fits-all so we have to find the consistent, repeatable and sustainable practices and processes while still allowing for customization that works for the customer. The easiest thing is knowing we're saving the planet with every panel we install, so it makes getting up in the morning exciting and easy, knowing we're going to leave a bunch more people better off than we found them every day.
Jordan Gietz
Often, there are challenges that arise specific to any given home’s structure that we cannot capture in a site survey. This could be anything from bringing various elements of a home up to code or the complexities of the electrical system within the home that can give us unexpected challenges. The easiest part about being in the residential solar industry is the demand. eEquals has found that many homeowners are increasing their interest in solar due to various motivators: rising energy costs, tax incentives or a growing awareness about sustainability. It makes our job that much easier when we have an eager and receptive customer base.
Tanya Hall
SOLAR INSTALLATION
SOLAR INSTALLATION TIPS
WHAT'S THE FIRST THING YOUR CREWS DO WHEN THEY ARRIVE AT A JOB SITE?
Every morning begins with a stretch session to warm up muscles and reduce the risk of injuries. Then, the superintendent conducts a meeting we call the “MAP meeting” — that stands for Morning Action Plan. At the MAP meeting, our team discusses the day's objectives, reviews potential hazards and determines how to eliminate them.
Geoff Greenfield, Director of Solar Strategy, Kokosing Solar
WHAT'S THE BEST WAY YOU'VE FOUND TO TRACK INSTALLATION PROGRESS?
We use a printed site plan posted on the wall, where we highlight or circle completed tasks in different colors. This provides a clear visual representation of progress and allows us to easily calculate the percentage of completion.
Michael Methot, Outside Superintendent of Commercial Construction, ACE Solar
Our crew leads in the field have iPads that they use to track their crew’s time against the various phase codes, which is then reviewed and approved by the jobsite superintendent. Our software generates weekly reports about the various labor inputs and equipment used which help us track the progress of a solar installation.
Geoff Greenfield
WHAT IS YOUR PREFERRED METHOD OF WIRE MANAGEMENT ON C&I SITES?
For C&I rooftop installations, we prefer using conduit (EMT/IMC) for a cleaner, more organized setup. When securing PV wire to the racking system, Heyco SunBundlers have become our go-to standard.
Bryan Tornetta, Program Manager, DCE Services
INSTALLATION TIPS
HOW DO YOU KEEP WORKERS SAFE WHEN HANDLING INCREASINGLY HEAVY PANELS?
SOLAR INSTALLATION TIPS
To enhance safety, we implemented a policy requiring two employees to handle and install heavier solar modules along with appropriate breaks. This approach reduces physical strain on individual workers and minimizes the risk of injuries, ensuring a safer work environment.
Bryan Tornetta
WHAT RECENT TECHNOLOGY HAS SIMPLIFIED INSTALLATION FOR YOUR COMPANY?
The development of manufacturer-provided apps for inverter programming and troubleshooting has significantly streamlined our installation process, improving efficiency and reducing downtime.
Michael Methot
Drone technology has significantly improved our surveying and layout accuracy, enhancing efficiency. Additionally, leveraging Procore for RFIs, submittals and scheduling has streamlined project management and installation processes.
Bryan Tornetta
HOW DO YOU DIVIDE WORK AMONG THE TEAM AT INSTALLATIONS?
We assign tasks based on skill levels, pairing crew members with complementary strengths. For example, if two team members excel in wire management, they are paired with someone less experienced to promote Michael Methot
Typically, jobs are sequenced from layout to material handling, then mechanical assembly and then electrical. It is critical that the teams are not slowing each other down, so understanding production factors of different crew sizes (and how weather conditions can impact them) is critical.
Geoff Greenfield
ACE Solar
UTILITY
Preparation is paramount for utility-scale solar installation, with thousands of repeated tasks across many acres.
HOW DOES YOUR COMPANY EVALUATE AND ADOPT NEW INSTALLATION TECHNOLOGIES, LIKE ROBOTIC AIDS?
When it comes to automation and technology, there's always a spectrum. Our workforce is important to us. We're never going to go fully automated. But there are a ton of innovations that can help us do the work better. For example, we’ve evaluated certain exoskeletons to help take the burden when lifting panels. We’re in the middle of the spectrum, trying to figure out what those tools are, whether they’re agnostic to certain technologies or designs, finding that happy medium of how we help our teams work better, faster, safer.
We pride ourselves on being innovative and being on the forefront of new technology, but that can be a huge burden to any company. McCarthy is super focused on an internal filtering process to ask where we really want to prioritize innovation. What is going to have the greatest ROI? There are so many things that we could spend a ton of time testing, and they’re all great in their own way, but what’s going to be best for us and have the largest impact? Over the last few years, instead of our focus being a mile wide and an inch deep, we’ve prioritized two or three things and deployed those on a single project here and there. Then, we can take a step back and see the results, how it worked, how it can be improved, if it can roll out on a large-scale. We don’t want to deploy something new on 500 MW. But we can map out a block here on this specific site and try it on 2 MW or a single tracker. We’ve explored a variety of things, and some haven’t worked out and that’s OK. We have to be willing to say the industry isn’t ready for it, or it needs a few more years.
Brett Foster, VP of Renewable Energy, McCarthy Building Companies
McCarthy Building Companies
INSTALLATION TIPS
WHAT ARE THE BENEFITS OF PREASSEMBLY ON LARGE-SCALE PROJECTS?
We've learned that labor is the most unpredictable and critical part in your estimating. If you get bad weather on a site and you’ve scheduled two weeks to build it, your cost overruns are catastrophic. What we learned doing a lot of these “smaller,” repeatable projects is that we had to kit it — kitting and pre-building rows in our warehouse. We have a 200,000-ft2 facility in Kansas where we pre-kit tracker rows. We know exactly every part that goes into a row, and we can put that row into a box so that when it comes off the truck, it gets deployed quickly out in the field. There aren’t any guys with hard hats sitting on buckets counting nuts and bolts and then bringing them out to the field. We've done that all within our control air-conditioned facility. We've done it with people who do it all day long, and their accuracy is very, very good.
Last year, we had over 5,000 truckloads of metal coming and going, so it’s a super busy time in our field, in our industry. We’re just trying to expand to keep up with it. We couldn't expand by hiring more mechanical contract labor. We felt like we could make the biggest impact and get more projects done by kitting and helping other people build fast and efficient.
Jay Miles, VP of Customer Excellence, Ampacity
SOLAR
Ampacity
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BASE
COMPACTFLAT
THE R_EVOLUTIONARY QUICK-CLICK MOUNTING SYSTEM FOR YOUR COMMERCIAL FLAT ROOF SOLAR PROJECT.
