and only factory that gathers all the stages of solar panel production under one roof, including
Solar panel production consists of four different stages; ingot, wafer, cell and
panel. Although these stages are the same all over the world, all the mentioned phases are gathered under one
single roof only in Kalyon PV.
Providing higher speed and quality standards, this gives Kalyon PV a unique
advantage in the solar energy sector.
Monocrystalline and multicrystalline methods are used worldwide in ingot production
technology. Despite its high investment and production cost, mono crystal stands out with its efficiency.
Prioritizing efficiency and quality, Kalyon PV prefers mono crystaline technology.
efficiency in multicrystalline cells remains at the level of 21%, in monocrystalline cells, the energy of the
sun beams and photons can be converted into electrical energy at values above 22 percent. Surface roughening
and coating processes are also meticulously followed throughout the process.
coating is done by vapor deposition in coating processes. This is a process that requires high level of
expertise, up-to-date know-how, encompasses many details and is carried out under various global patents.
obtained by processing the silicon found in sand is utilized as raw material in the production of the ingots.
Polysilicon is melted at 1450 degrees Celsius in specialized machinery. Through this process, mono-crystalline
silicon is turned into ingots. Utilizing specially prepared equipment and advanced engineering techniques, the
melted raw material is then turned into a cylinder weighing about 400 kilograms and measuring at a height of
approximately 4 meters. This conversion is calculated in millimeters. An advancement of 5 to10 millimeters per
hour can be made. As the purity obtained during the production phase increases the quality of the end product,
the production area sterilization is also carefully monitored throughout the process.
At this phase,
also called the plate, the obtained ingot is put into work. To begin with, the extremities of the cylindrical
product (head and tail) are separated from the body. Subsequently, the edges are cut and an angular shaped
nugget roughly measuring about 3 meters is revealed.
The ingots produced are sliced at a thickness of
170 microns by diamond-coated, wire saws 55 microns thick at speeds of 15 meters per second. The wafer, which
is attained by using advanced technological equipment, is then separated by particular procedures.
It is the phase
in which the obtained wafers are transformed into high-tech products. The silicon slices processed in the cell
factory are passed through more than 30 different chemical and physical semiconductor production procedures
and thus obtain photovoltaic solar cell attributions. Its two surfaces are suited to produce sunlight into
electrical energy. The front surface converts direct sunlight into electricity, while the back surface
accumulates the reflected sunlight.
In the final
phase, the solar panel is produced by combining the cells. Depending on the panel to be produced, 54 (108
half-cells) or 72 (144 half-cells) cells are soldered to each other on a special surface, again by application
of specific techniques. The solar panels, in which silicon metal is processed and turned into a high-tech
product, are converted into highly efficient items in energy production that are suitable for all kinds of
climate and field conditions.