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.

Whereas the 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.

Nanometer level 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.

Phase one
ingot production

Polysilicon 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.

Phase two wafer

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.

Phase three cell

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.

Phase four panel

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.