AI and automation are rewriting the rules of solar manufacturing

The company will unveil its latest TOPCon modules with 210R cells, alongside lightweight rooftop modules, at REI 2025.

The push for solar self-reliance is shifting beyond module assembly toward comprehensive value-chain manufacturing, encompassing wafers, cells, and advanced equipment. Rayzon Solar is enhancing quality, predictive maintenance, and efficiency with the help of AI and automation. The company will unveil its latest TOPCon modules with 210R cells, alongside lightweight rooftop modules, at REI 2025. Let us hear from Hardik Kothia to know more insights.  

What does self-reliance in India’s solar manufacturing entail, and how are automation and AI reshaping production and maintenance?

Self-reliance for solar manufacturing in India means not only assembling solar modules but really going back into the value chain of manufacturing components. It also involves local innovation in terms of new technologies and manufacturing equipment for these components. This will ensure that our dependency on the variability of the global supply chain does not negatively impact us.

Moreover, AI and automation are rewriting the rules of solar manufacturing. On our production floors, AI, in conjunction with machine vision systems, catches the smallest of micro-cracks, soldering anomalies, or busbar defects that even the most skilled human eye might miss. Predictive AI models analyse data from thousands of sensors and alert us before a machine goes down, reducing downtime and improving yields. This shift is not cosmetic — it directly boosts efficiency, lowers costs, and gives customers greater reliability. Every incremental improvement in uptime and quality translates into a stronger push toward energy independence in India.

How does Rayzon maintain production during supply disruptions, and can India become a hub for modules and upstream solar components?

Disruptions are no longer the exception; they have become the norm. At Rayzon, we have built a strategy on three pillars: diversify, localise, and partner long-term. We source from multiple countries and vendors, ensuring that no single bottleneck halts production. We are expanding our domestic cell and module capacity, while also venturing into Aluminium extrusion and anodising for module frames. And have signed strategic contracts that guarantee supply in volatile markets.

However, India’s solar journey started with module assembly, but the natural next steps are cells, wafers, and ingots. The capital requirements are high, but so is the determination. With a strong government push and favourable policies like PLI and ALMM, the ecosystem is already moving upstream, with huge investments coming from multiple manufacturers to expand in the value chain. Within this decade, India has every chance to be a fully integrated hub for the world.

How will utility-scale and rooftop solar demand shape module efficiency and installation trends in India?

Utility-scale will remain the volume driver, pushing demand for larger, more efficient modules that bring down LCOE. But rooftops will be the innovation frontier demanding lighter frames, smart monitoring, and faster installation. Utility-scale would continue its dominance, with huge capacity additions that we foresee in the near future, as well as on a mid-term basis.

What are you showcasing at REI 2025?

At REI 2025, we want to showcase solutions that work today, not just prototypes. We are unveiling our latest TOPCon modules, featuring 210R cells, which deliver higher efficiency for utility projects, alongside lightweight rooftop modules designed for commercial and industrial (C&I) and residential use. We will also demonstrate our AI-driven quality inspection system and predictive maintenance dashboard, both of which are already deployed in production.

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