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					</table>The rapid evolution of solar module technology is driving changes in photovoltaic (PV) junction box design, with manufacturers moving from conventional single-box configurations toward split-box designs and higher current ratings to accommodate high-wattage modules.
Industry experts say further technological development will depend significantly on the performance and availability of suitable bypass diodes. Material quality is also becoming increasingly important as manufacturers face pressure to reduce costs.
Junction boxes form part of a solar module&#8217;s electrical system, housing bypass diodes and connections that carry electricity from the module.
The Shift to Split-Box Designs
As module wattages and current levels increase, junction box designs and component specifications are evolving to accommodate changing electrical characteristics.
The market is currently seeing widespread adoption of three-piece split junction-box configurations, with 30A and 35A current ratings becoming common for high-power modules. Schottky SMD bypass diodes are widely used because their lower forward voltage helps reduce power dissipation and heat generation during forward-bias operation.
According to Shyam Talsaniya, Head of Technology at <a href="https://orinpv.com/" target="_blank" rel="noopener">Orin Group</a>, 1500V system voltage is currently widely used, while 2000V systems are also beginning to emerge. Junction boxes designed for 2000V applications require improved electrical insulation, higher creepage and clearance distances, and suitable materials to ensure adequate dielectric strength and long-term insulation reliability.
“Another emerging trend is the development of smart junction boxes, which can incorporate sensing and control electronics to monitor parameters such as module current, voltage, power, and temperature. Depending on the system architecture, these solutions can also provide power-control or shutdown functionality when required, enabling improved module-level monitoring, protection, and system safety,” Talsaniya added.
Overall, the technology is moving toward higher current and voltage capability, improved thermal and insulation performance, smarter monitoring and control, and more compact split-box designs.
Mahipalsingh Gohil, Co-founder and Executive Director at <a href="https://www.sparkhubrenewables.com/" target="_blank" rel="noopener">Sparkhub Renewables</a>, said junction boxes require updated diode specifications to keep pace with rising module wattages. Earlier, current ratings of around 20 A to 25 A were common.
Junction boxes traditionally used single-chip diodes, but manufacturers are increasingly moving toward double-chip diodes for higher current requirements.
The diode-to-cable connection process is also changing. Manufacturers that once relied primarily on crimping are increasingly combining crimping with soldering.
“This improves connection durability and supports better electrical performance. It is also being adopted to improve the junction box&#8217;s overall durability and reliability,” Gohil said.
Talsaniya noted that as module wattages increase, both voltage and current ratings tend to rise, with current becoming a greater challenge to accommodate. For higher-current junction boxes, such as 35A designs, better-performing SMD bypass diodes, including dual-trench configurations, are required to achieve lower forward voltage and minimize heat generation.
“Diode heat dissipation also needs optimization through appropriate thermal fins, copper plates, and heat-transfer paths. In parallel, junction-box plastics need higher RTI (Relative Thermal Index) and better weather/UV resistance to ensure that any heat generated during operation does not accelerate material degradation,” he added.
Aru Aditya Vasu, CEO at <a href="https://arbon.co.in/" target="_blank" rel="noopener">Arbon Cleantech</a>, said ratings have increased from around 30 A toward 35 A, with the possibility of even higher ratings in the future. Junction box technology is also evolving alongside module technologies such as TOPCon and back-contact designs. As module current and voltage requirements increase, junction box designs, internal components, and polymers must also evolve.
Gohil observed that most TOPCon modules currently being manufactured use split-box configurations, while manufacturers developing future module technologies are also largely experimenting with split designs.
“Conventional single junction box designs are gradually becoming outdated for newer module configurations,” he added.
Vasu commented that the transition is already well advanced, estimating that split junction boxes account for the majority of the Indian market. Conventional single-box designs are now largely restricted to smaller modules used in applications such as streetlights, and several manufacturers have stopped producing them altogether.
Split-diode junction boxes can be used with mono PERC, TOPCon, HJT, and other high-wattage modules, with product selection primarily determined by a module&#8217;s electrical specifications and design requirements.
Talsaniya added that in India, adoption of split-diode configurations became noticeable around 2020, and the shift has become clearer with growing module sizes and the adoption of half-cut cell configurations. “The key advantage is that the electrical and thermal load is distributed across multiple junction boxes, resulting in lower heat generation per junction box. In addition, the busbars connecting the junction boxes do not need to travel the longer distances associated with a single-box configuration. This can reduce looping losses and associated electrical resistance, improving the module&#8217;s overall electrical design.”
Quality Versus Cost
Junction boxes are high-volume, low-margin components, making automation increasingly important for manufacturers seeking to improve production efficiency while maintaining competitive pricing and consistent quality.
Domestic manufacturers also face significant price competition from Chinese suppliers. Industry participants caution that aggressive cost reduction can create reliability risks if manufacturers compromise on housing materials, connectors, or diodes, potentially leading to failures over a module&#8217;s operating life.
“Indian module manufacturers are increasingly open to domestically produced junction boxes. However, supplier qualification remains lengthy, as components must be included in the approved bill of materials and supported by the required documentation, testing, and certifications. The approval process can take nearly a year, limiting new manufacturers&#8217; ability to scale even when production infrastructure is available. Local manufacturing can improve quality inspection and compliance verification, but dependence on Chinese raw materials remains a major challenge,” noted one manufacturer.
Domestic Manufacturing Expands
India&#8217;s junction box market is expanding alongside domestic solar module manufacturing.
India now <a href="https://www.mercomindia.com/solar-module-capacity-under-almm-rises-to-228-gw" target="_blank" rel="noopener">has</a> around 225 GW of Approved List of Models and Manufacturers (ALMM)-compliant module capacity.
Gohil said junction box manufacturers are planning around 40 GW of additional capacity. As this comes online, domestic production could meet a significant share of module manufacturers&#8217; requirements, reducing dependence on imported junction boxes.
However, the expansion of module manufacturing capacity does not necessarily translate into equivalent near-term junction box demand because actual annual module production and solar installations remain significantly below announced manufacturing capacity.
Vasu noted that India&#8217;s domestic junction box manufacturing capacity is already estimated at more than 100 GW and is broadly sufficient to meet current requirements. Imports nevertheless continue to compete with locally manufactured products, while some domestic production facilities remain underutilized.
Localization Challenges
The expansion of India&#8217;s module manufacturing base is creating opportunities to localize junction boxes and other components such as encapsulants, backsheets, and frames.
Talsaniya observed that a major challenge is the availability of high-current bypass diodes. These are specialized semiconductor components that are not commonly used in other applications. India currently lacks sufficient manufacturing capacity and capability to produce these diodes at the scale, cost, and quality required for reliable, commercially viable junction boxes. As a result, current production remains heavily dependent on imported diodes.
“Another challenge is injection-molding capability for small and intricate junction-box components. The molding process requires precise tooling and process control, and the industry still relies heavily on overseas molds. When design changes, development work, or modifications are required, this dependence can lengthen timelines. Hence, strengthening domestic capabilities in precision mould manufacturing, mould maintenance, and specialized injection molding would be important for reducing development lead times and supporting the scale-up of India&#8217;s junction-box manufacturing ecosystem,” Talsaniya added.
Gohil said the tax and duty structure on finished junction boxes and the raw materials domestic manufacturers use can put local producers at a disadvantage. Certain raw materials imported from China, for example, can attract GST of around 18%, while a 1,500 V DC junction box is sold at around 5% GST. This can narrow the price difference between imported finished junction boxes and domestically manufactured products.
“Policy support that creates a more balanced duty structure for imported finished junction boxes could help domestic manufacturing expand,” Gohil said.
Compared with modules, cells, and glass, the junction box segment has relatively limited support through duties, standards, or manufacturing incentive programs.
Industry participants suggest that greater emphasis on value-based procurement and minimum domestic sourcing requirements could support local component manufacturing. They argue that such measures could strengthen quality control while reducing the solar manufacturing industry&#8217;s dependence on imported supply chains.

Solar Modules Are Getting More Powerful: Junction Boxes Must Keep Up

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					</table>India has rapidly expanded domestic solar module manufacturing, while investments in cells, ingots, and wafers continue to gather pace. However, achieving a truly self-reliant manufacturing ecosystem will also require domestic production of ancillary components, including junction boxes, interconnect busbars, encapsulants, sealants, solar glass, aluminum frames, and DC cables.
In an interview on the sidelines of the <a href="https://www.mercomindia.com/event/mercom-india-renewables-summit-2026" target="_blank" rel="noopener">Mercom India Renewables Summit 2026</a>, Bhupendra Singh Rawat, Chief Executive Officer at <a href="https://dhashgreen.com/" target="_blank" rel="noopener">Dhash Green Energy</a>, discussed India’s ancillary manufacturing ecosystem, product reliability, quality standards, policy support, and the company&#8217;s expansion plans.
Edited excerpts from the interview.
How important is it to build a fully self-reliant domestic supply chain for the bill of materials and balance-of-system components as India scales up solar manufacturing?
Manufacturing is fundamental to every economy, and a complete value chain, including ancillary manufacturing, is essential for long-term competitiveness.
India has already made significant progress. Module manufacturing capacity now largely meets domestic demand; cell manufacturing is receiving greater emphasis; and the government has already announced the inclusion of ingots and wafers in the domestic manufacturing framework from 2028.
In ancillary manufacturing, India has already achieved a high degree of self-reliance in products such as junction boxes, encapsulants, interconnect busbars, sealants, solar glass, and aluminum frames.
Developing these capabilities is no longer only an industrial priority. Energy has become a matter of national security, making a resilient domestic supply chain strategically important.
How do junction boxes, connectors, and cables contribute to the reliability of a solar project?
Solar modules are backed by warranties of up to 30 years. Every component used in a module must therefore deliver comparable long-term reliability.
The products must undergo mechanical, electrical, and thermal stability testing. They must also be tested under humidity-freeze cycles, thermal cycling, ultraviolet exposure, and other environmental conditions. Manufacturers need strong in-house testing capabilities to ensure that products can withstand different temperatures, humidity levels, and diverse operating environments throughout the module’s life.
Dhash has invested in both scale and quality infrastructure. We have 63 GW of junction box manufacturing capacity and 25 GW of interconnect busbar capacity.
We are also backward integrated into plastic injection molding for junction boxes. In DC cables, we are establishing a capacity of 1,000 km per day using electron-beam cross-linking technology.
Each product line has its own laboratory for regular testing and long-term reliability assessments. This provides module manufacturers greater confidence in the quality and durability of the components.
Are these testing facilities available in-house?
Yes, all these facilities are in-house. We are also applying for accreditation from the National Accreditation Board for Testing and Calibration Laboratories. An in-house testing facility is critical for any solar ancillary manufacturer. Quality should be embedded in the product by default.
Given the 30-year warranties offered on solar modules, every component must be capable of operating reliably under heat, humidity, temperature fluctuations, and varying climatic conditions throughout the project’s life.
India continues to depend on imports for several solar components. How quickly is domestic manufacturing catching up?
The transition is already underway. Dhash currently has about a 50% share of India’s junction box market. India has approximately 153 GW of installed junction box manufacturing capacity, which is sufficient to meet domestic module manufacturing requirements.
We entered interconnect busbar manufacturing only around five months ago and have already scaled our capacity to 25 GW. Within the next few quarters, we expect domestic production in this segment to be sufficient to support the module industry.
Other components are also catching up. Domestic sealant and encapsulant capacities have each crossed around 60 GW.
India’s current annual module demand is estimated at around 65-70 GW. Most domestic component categories are approaching that level of capacity. Solar glass may take longer due to a longer project development and commissioning cycle, but capacity is also being developed in that segment.
India is steadily moving toward self-sufficiency across the component value chain.
How has demand for domestically manufactured solar components changed in recent years?
Demand has increased significantly. Over the past two financial years, Dhash Technologies has supplied around 40 GW of junction boxes. We supplied approximately 15 GW in the financial year 2025 and around 25 GW in the financial year 2026.
This growth reflects the confidence that domestic module manufacturers have placed in Indian component suppliers. Our responsibility is to maintain that confidence by delivering reliable products, continuing to innovate, and ensuring compatibility with future solar technologies.
Should the government introduce an approved list or quality-linked framework for solar components?
India’s module manufacturing capacity expanded rapidly after the Approved List of Models and Manufacturers framework was implemented. ALMM List-II for solar cells is expected to encourage capacity additions, with substantial cell manufacturing capacity already committed by the industry.
Ancillary manufacturing needs a similar policy framework. The government could consider an approved list of ancillary manufacturers to encourage investment, ensure quality, and accelerate capacity expansion.
In addition, products such as junction boxes should be brought under Bureau of Indian Standards certification as complete products. At present, only DC cables are directly covered by product-specific standards.
What regulatory framework would you like to see for BoM and BoS components?
The first priority is product-specific classification. Many components used by the renewable energy industry are currently imported under generic Harmonized System of Nomenclature codes. This makes it difficult to accurately assess how much is being imported and how much is manufactured domestically.
Junction boxes, for example, are imported under generic tariff classifications. Interconnect busbars may enter India under several different HSN codes because no single product-specific code exists.
The government should introduce dedicated HSN codes for key renewable energy components. This would improve monitoring, transparency, and policy enforcement. We would also like to see a minimum Basic Customs Duty of 20% on these components to prevent dumping and create a level playing field for domestic manufacturers.
Junction boxes should be covered by BIS certification as a complete product. Standards for interconnect busbars are also being developed, and we are in discussions with the National Institute of Solar Energy. Once finalized, these products should also be brought under BIS.
What are Dhash Technologies’ plans for the next five years?
We are focused on remaining technology-ready as module technologies continue to evolve. Our junction boxes are compatible with mono PERC, TOPCon, heterojunction, and other emerging module technologies.
We are also developing innovative interconnect busbar products, including reflective and elliptical busbars. These designs can improve solderability due to their larger effective contact area with solar cells.
Another major product is a composite module frame, which we believe can become a transformational solution for moisture-prone and demanding environments such as Khavda and floating solar projects.
Composite frames can offer significant advantages in corrosion resistance, carbon footprint, manufacturing efficiency, and pricing.
We have commercially launched the product and are the exclusive partner of a leading global glass-roving material manufacturer. We plan to begin manufacturing the composite frames in India within the next six to eight months.

Domestic Solar Components Need Quality Standards and Policy Support: Interview

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					</table>In an interview on the sidelines of the <a href="https://www.mercomindia.com/event/renewables-summit-2025" target="_blank" rel="noopener">Mercom India Renewables Summit 2025</a> held in New Delhi on July 24 and 25, 2025, Avinash Hiranandani, Vice Chairman and Managing Director at <a href="https://www.renewsysworld.com/" target="_blank" rel="noopener">RenewSys</a>, shared his insights on India’s solar cell and module, and components manufacturing. He also gave an overview of his company’s products and plans for expansion.
India has set a goal of 500 GW of non-fossil fuel energy capacity by 2030. How do you see RenewSys contributing to this goal? 
RenewSys has been in the market for more than 10 years. We started off by making encapsulants and backsheets. We have supplied close to 30 GW to the Indian and overseas markets. So, we are an important part of the solar manufacturing sector in India.
We have also been supplying cells and modules, and today we have 5.5 GW module manufacturing capacity ready to start by September. We are also starting our TOPCon cell manufacturing facility. RenewSys has always been supplying high-quality products to the Indian market, and we will continue doing so to help India achieve its 2030 targets.
<iframe loading="lazy" title="Interview with Avinash Hiranandani, Vice Chairman &amp; Managing Director at RenewSys India" src="https://player.vimeo.com/video/1109283155?h=8af03acbf4&amp;badge=0&amp;autopause=0&amp;player_id=0&amp;app_id=58479" width="100%" height="500" frameborder="0">﻿﻿</iframe>
How do you view the current solar module and cell manufacturing landscape in India? 
Today, solar module capacity as per the Approved List of Models and Manufacturers is about 90 GW plus. Solar cell capacity is close to 25 GW in the market and growing very fast. Many small players are also in the market, catering to small capacities. Large-scale projects can be executed much faster if these players become bigger.
What are RenewSys’s plans for expanding the capacities of encapsulants and other components?
Currently, we have 10 GW and are planning to add another 10 GW. With a pipeline of another 10 GW, we will reach 30 GW. We will be adding 20 GW more to reach 50 GW of encapsulant capacity. We are also making transparent back sheets. Transparent backsheets also play a very important role in the market, and they are ready to be supplied.
What is domestic demand like now?
The domestic demand for modules is 90 GW. Some of the components still come from free trade countries and from China. But many players have now realized that sometimes the containers take a lot of time to arrive. The products may also get spoiled in transit. RenewSys makes encapsulants every day. So, the products are fresh.
Are there any quality standards that have been set up for encapsulants and other components in India?
There are IEC standards, and RenewSys has its own standards. We conduct reliability tests on our products. We only sell those products that we use ourselves. That is how we have maintained our leadership position in the Indian market. However, there are no government standards for components like aluminum frames and junction boxes.
Solar developers have been complaining about the unavailability of modules compliant with domestic content requirements. How do you see this situation? 
The government has created the demand for DCR modules, and the industry is playing catch-up. Something must start first. If there is no demand, there is no production. There will be periods when you cannot have both demand and supply equally.
When ALMM was introduced, there was hardly any capacity module capacity available. At that time, developers were saying there was not enough capacity available, but now they are saying there is overcapacity.
So, when policies are introduced, demand will follow. You cannot set up capital expenditure-intensive cell lines in the hope that the policy will follow.
With ALMM for cells also coming into effect from June 2026, do you think the Indian manufacturing industry will be able to cope with the demand?
The government is already taking data from manufacturers. It will probably decide whether June 2026 should be the date or whether it should be postponed by three months or six months. That is a call the government will take. Probably with a three to six-month postponement, I think the capacities will come up.
The government is also focusing on backward integration in the solar ecosystem. What are RenewSys’ plans for this? 
There is limited support for other products, such as junction boxes, aluminum frames, and encapsulants. The government is in regular contact with us to determine what support can be provided. Then you&#8217;ll see the ancillary industry booming, just like solar manufacturing boomed.
India doesn&#8217;t have a clear target beyond 2030 for renewable energy. What do you think India&#8217;s capacity should be by 2040? 
India should add 250 GW of manufacturing right across the solar sector every year. So, there is still significant scope for growth. Solar is not overcrowded. In the long run, there is sufficient space for everyone to participate and for larger players to also enter and develop the solar value chain in the country.
(Note: Sections of the interview have been paraphrased for better reading. Check out the video for a full chat)

Solar Cell Demand Can be Met with a Short Deadline Extension if Needed: Interview

The <a href="http://www.pgvcl.com/" target="_blank" rel="noopener noreferrer">Paschim Gujarat Vij Company</a> (PGVCL) has issued an expression of interest (EoI) for empaneled agencies to set up 600 MW of grid-connected rooftop solar photovoltaic (PV) projects in residential premises.
The date for the pre-bid meeting is July 25, 2019, and the last date for the submission of the bids is August 6, 2019.
Bidders are required to quote the rates inclusive of a comprehensive maintenance contract (CMC) for five years.
For Category A bidders, the earnest money deposit (EMD) totals to ₹700,000 (~$10,150), for non-micro small and medium enterprises (MSMEs) units it is ₹700,000 (~$257), and for MSMEs, it will be ₹4,00,000 (~$5,800).
Bidders who come under Category B need to pay ₹400,000 (~$5,800) as EMD. They’re expected to have an experience of installing solar rooftop or grid-connected systems in any of the sectors such as residential, social, industrial, commercial, or government.
According to PGVCL, the rates invited are for eleven system capacities of solar systems: 1 kW, 2 kW, 3 kW, 4 kW, 5 kW, 6 kW, &gt; 6kW to 10 kW, 10 kW to 25 kW, 25 kW to 50 kW, 50 to 100 kW  and  &gt;100 kW.
As per the PGVCL, the successful bidders should pay a non-refundable amount of ₹25,000 (~$363) including the GST towards empanelment fees which will be followed by a letter of empanelment.
According to PGVCL, Category-A bidders are those who have experience of successful installation and commissioning of at least 100 kW capacity of solar systems in any sector such as residential, social, industrial, commercial, and government.
Those bidders who fall under Category A should have an average turnover of ₹5000,000 (~$72,550) in the last three fiscal years.
In the scope of work,  the PGVCL has stated that the work is to be carried out on a turnkey basis which includes identification of the beneficiary in the residential category,  survey of the site for its feasibility, sanctioned load of the beneficiary by the DISCOM, design, supply of the solar systems (with all other accessories, equipment and protection devices), installation, testing, commissioning. The responsibility would also include maintenance services for five years.
As far as the technical specifications are concerned, solar PV projects should consist of the required number of crystalline PV modules, grid-interactive power conditioning units, mounting structures, junction boxes, solar meters to name a few.
According to the PGVCL, the modules and solar cells used for this program should be domestically manufactured as per the Ministry of New and Renewable Energy’s (MNRE) requirement.
The total solar PV array capacity should comprise solar crystalline modules of minimum 250W. Modules with a capacity less than 250W will not be accepted states PGVCL.
During the recently held <a href="https://mercomindia.com/gujarat-new-budget-rooftop-solar/" target="_blank" rel="noopener noreferrer">state budget session</a>, the Gujarat government emphasized on the rooftop solar projects and announced a recalibrated target of 30 GW renewable capacity by 2022. The goal includes both solar and wind.
Mercom reported recently that the <a href="https://mercomindia.com/gujarat-ppa-solar-projects/" target="_blank" rel="noopener noreferrer">Gujarat Electricity Regulatory Commission</a> had approved the power purchase agreements for 500 MW of grid-connected solar projects. The solar PV projects will be developed under Phase III of the state’s Raghanesda Solar Park.

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