Emerging Technology Trends Driving Efficiency in Solar PV Systems

Efficiency Gains: Emerging Technology Trends in the Solar PV Space
July 1, 2025
By Suhas Donthi, President and Chief Executive Officer, Emmvee Group

As the world accelerates its transition to clean energy, solar power is emerging as a cornerstone of global energy transformation. At the heart of this shift is solar photovoltaic (PV) technology, which is continually evolving to become more efficient, cost-effective, and scalable. For India, which boasts one of the largest solar potentials in the world and ambitious clean energy targets, the rise of next-generation solar PV technologies presents both significant opportunities and challenges.

### Current Landscape: The Power Behind Today’s Solar Modules

The solar PV market is currently dominated by silicon-based technologies, particularly passivated emitter rear cell (PERC) modules. These modules are widely adopted due to their high efficiency, reaching up to 23.8 percent, and their compatibility with existing manufacturing setups. PERC modules account for over 70 percent of the solar modules produced in India. Following PERC are tunnel oxide passivated contact (TOPCon) cells, a more advanced version that can achieve efficiencies exceeding 26 percent by reducing electron recombination. Many Indian manufacturers are transitioning to TOPCon due to its superior long-term performance and reliability.

Heterojunction technology (HJT), which combines crystalline silicon wafers with amorphous silicon layers, is gaining recognition for its potential to deliver efficiencies between 25 percent and 26.5 percent. However, challenges such as high production costs and reliance on scarce materials like indium and silver persist. Another emerging technology is tandem solar cells, especially those that integrate silicon with perovskite layers, which have already achieved efficiencies surpassing 28 percent in laboratory tests. Nonetheless, issues related to stability, toxicity (due to lead content), and large-scale production remain unresolved.

### India’s Solar Surge: Trends and Adoption

India is currently witnessing an unprecedented solar boom. As of May 2025, the country’s installed solar capacity had reached nearly 110 GW, making it a critical component of its non-fossil energy mix. The government aims to achieve 500 GW of non-fossil capacity by 2030, with around 280 GW dedicated to solar power. To achieve this ambitious target, domestic production is rapidly expanding. India already has approximately 80 GW of module capacity and 15 GW of cell manufacturing capacity, with projections to reach 160 GW of module capacity and 120 GW of cell capacity by 2030.

Leading companies like Emmvee, Tata Power Solar, Vikram Solar, Waaree, Adani, and Reliance are driving this growth by introducing advanced technologies and establishing integrated manufacturing units. Additionally, India’s increasing solar exports to the US and other markets signal a shift towards becoming a global solar hub, contingent on the right technologies and policy environment.

### Enhancing Efficiency: The Next Frontier

Improving efficiency is crucial for solar manufacturers and researchers. Here are some ways the industry is addressing this challenge:

– **Next-generation architectures**: Technologies such as TOPCon, HJT, and perovskite-silicon tandems promise efficiencies of 28-30 percent, surpassing the 22-23 percent limit of traditional PERC modules.
– **Advanced cooling techniques**: As solar panels heat up, their efficiency declines. Innovations like passive cooling systems, phase-change materials, and water-air hybrids help reduce heat-related losses and enhance performance.
– **Material substitution**: Replacing costly and scarce materials like silver and indium with alternatives such as copper and more abundant elements can lower costs and improve scalability.
– **Automation and larger wafers**: The adoption of larger wafers (like M10 or G12) and laser-enhanced manufacturing techniques boosts production efficiency and reduces per-watt costs.

### Domestic Manufacturing: Progress and Gaps

While India’s module manufacturing capacity is growing, the cell-to-module ratio remains low, and critical upstream inputs like polysilicon, wafers, and ingots are still largely imported. The production-linked incentive (PLI) scheme and the Approved List of Models and Manufacturers (ALMM) have supported capacity building; however, an integrated value chain from quartz mining to wafer and cell manufacturing is still developing. Although India has commenced domestic polysilicon production, vertical integration is still a few years away. Geographic dispersion among manufacturers adds logistical costs and limits ecosystem synergy, leading to a consensus that India should adopt cluster-based development models, similar to its automotive and semiconductor sectors.

### Challenges Faced

Despite robust growth, Indian solar manufacturers are confronted with several structural challenges:

– **Skilled workforce shortage**: The industry is projected to require 1.7 million solar professionals by 2027. Current training programs like Suryamitra need significant scaling and modernization.
– **Grid and land constraints**: Inadequate transmission infrastructure and complex land acquisition processes hinder the development of solar parks. Distributed solar projects also face challenges with net metering and compliance issues.
– **Low tariffs and financing barriers**: Reverse auctions lead to low tariffs, compressing developer margins and discouraging investment in innovative technologies.
– **Supply chain vulnerabilities**: Continued reliance on imported wafers, glass, and specialty gases exposes the industry to price volatility and geopolitical risks.
– **E-waste regulation gaps**: With solar panels having a lifespan of 25-30 years, India is expected to generate over 1.8 million tonnes of solar PV waste by 2050, necessitating a formal recycling policy.

### Policy Recommendations

To sustain and expand the growth of solar PV technologies in India, the following policy interventions are essential:

– **Skill development programs**: Expand and standardize training for solar technicians to meet current and future workforce needs.
– **Increased R&D funding**: Invest more in solar research and development through institutions like the National Institute of Solar Energy and IITs and foster global technology partnerships.
– **Incentives across the value chain**: Extend PLI benefits to include polysilicon, wafers, and ingots, not just cells and modules.
– **E-waste management policy**: Establish a regulatory framework for recycling PV modules and incentivize the development of recycling infrastructure.
– **Stable policy environment**: Ensure consistency and clarity in ALMM guidelines, import duties, and net metering regulations.
– **Innovative financing support**: Provide low-interest loans, rooftop solar subsidies, and green bond mechanisms to encourage both utility-scale and residential adoption.

### The Road Ahead: India’s Solar Future

India’s solar journey is at a pivotal moment. With emerging technologies like TOPCon, HJT, and perovskite-silicon tandems set to redefine efficiency standards, the country has a unique opportunity to advance into the next era of solar power leadership. Government policy is trending positively, domestic manufacturing is maturing, and there is a growing appetite for innovation. However, to genuinely lead in the global solar race, India must create a resilient and self-sufficient ecosystem rich in capacity, technology, talent, and sustainability. With the right combination of innovation, investment, and policy intent, India is well-positioned to become a global powerhouse in solar PV technology.