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France also relies on the power of the sun
On the road to the energy transition, the French government is also aiming to significantly expand photovoltaics. One important manufacturer of solar modules is Voltec Solar in Dinsheim-sur-Bruche, not far from Strasbourg. Since 2009, the supplier has been producing PV modules on three production lines, mainly for the French market. Customers or buyers are project developers, but also building material dealers or PV installers as well as municipalities and companies that are reached through tenders. In order to optimize production, those responsible purchased a so-called easy-Lam single-daylight laminator from Bürkle a good ten years ago, as the machine manufacturer from Freudenstadt is considered one of the leaders in this segment. Five years later, a first Ypsator followed and last year finally the second Ypsator, the latest model 2226-6 SL, because Voltec's ambitious goal is to be the leader on the French market one day.
All three machines were integrated into the existing production lines without any problems. The assembly and installation of the new system took just under five weeks, while the entire planning and commissioning period lasted around two years. The new laminator for Voltec measures an impressive 19 meters in length, 6 meters in width and 3.20 meters in height. The first heating stage alone, the heart of the entire system, weighs 45 tons.
The two Ypsators have a multi-level design, which makes them particularly interesting for manufacturers with limited space, as they guarantee a high output in a comparatively small production area. The latest Ypsator has six levels.
The new Ypsator is designed in such a way that two PV modules can enter each floor at the same time. As a rule, the solar modules produced in France have a maximum size of 1.265 by 2.200 meters. This in turn results from the format of the so-called waver, the actual solar cells. At Voltec, the PV modules are made of highly resistant glass and also have a reinforced frame. The cable length is shorter than with comparable other modules, which should simplify installation. In addition, a non-destructive cell cutting process is used to enable loss-free partial disconnection. One contribution to environmental protection is the use of films for the rear side that do not contain any toxic fluorine. This prevents damage to the environment and health if, for example, the building should catch fire.
Laminating with overpressure
A total of two different press technologies are integrated in both Bürkle Ypsators. In the first step, the air between the individual layers is removed in the vacuum press. The modules are also pre-laminated and sealed during this process. The Ypsator works with pressures of 500 to 1,450 millibars, which in turn enables very short process times. The ability to work with overpressure during production is another unique selling point of the laminators from Freudenstadt. Thermal oil is used to heat the press.
After the actual laminating process, the modules are cooled in the Ypsator. The modules are cooled down to below 40 degrees Celsius in a controlled cooling stage using water. The process time in the Ypsator from entry to the finished lamination of the PV modules only takes up to 6.5 minutes.
Daniel Klaus emphasizes that the cleaning and maintenance intervals always depend on the material used, so there are daily, weekly and even fixed monthly maintenance intervals in order to keep the production process at the same high level without downtime. Of course, the three systems run practically around the clock. The currently delivered Ypsator 2226-6 SL laminates an average of over 2,200 PV modules per day.
Michaël Godet, Deputy General Manager of Voltec Solar, is delighted with the new Ypsator: "We were immediately impressed by the line performance. And this combined with the fact that Bürkle was again able to supply us with a completely customized system exactly according to our needs. We have always had a very positive experience of working with Bürkle over the past few years, so our confidence in the entire Bürkle team is very high."
The long-standing cooperation with Bürkle is also an integral part of the supplier's strategy. "In terms of price, we can hardly keep up with the competition from Asia. That's why we take a different approach, because we offer our customers a so-called low-CO2 range. This means that we source our raw materials and machinery exclusively from Europe. Our PV modules are therefore more environmentally friendly overall than those produced abroad, as they do not have to travel halfway around the world, figuratively speaking. And we are very fortunate that many of our customers are prepared to pay a certain premium price, as this secures jobs here in the country," concludes Michaël Godet.
