A Glimpse into Bluebird's Manufacturing Excellence & Half Cut PV Module Launch

7 min read
Bluebird Solar Plant Visit

In a world grappling with the challenges of climate change and energy sustainability, the quest for cleaner and more efficient energy sources has taken centre stage. Solar energy, in particular, has emerged as a promising solution to mitigate environmental impact and reduce our dependence on fossil fuels. 
In this regard, Bluebird Solar, a leading player in the renewable energy sector, has made a significant stride by launching an extensive range of Mono-facial and Bi-Facial Half-Cut solar PV modules. These modules come in various cell configurations, from 108 cells to 144 cells, offering an impressive power output that promises to revolutionize the solar energy landscape.

Bluebird Solar's Commitment to Sustainability

With its unwavering commitment to sustainability, Bluebird Solar has long been at the forefront of driving solar energy adoption. The company's mission is to provide high-quality solar pv modules that are not only efficient but also environmentally friendly. With the introduction of these new solar PV modules, Bluebird Solar aims to empower individuals and businesses alike to embrace clean energy solutions, reduce carbon footprints, and contribute to a greener future.

Plant Visit Event: A Glimpse into Bluebird Solar's Manufacturing Excellence

To showcase their dedication to quality and innovation, Bluebird Solar organized a plant visit event from October 4th to October 6th, 2023. The event was held at their fully automated manufacturing unit that spreads across 5 acres of area in Greater Noida, Uttar Pradesh, India. It attracted more than 250 Solar EPC companies and wholesale traders from across the country.

The plant visit event served as an opportunity for attendees to witness firsthand the cutting-edge technology and meticulous processes that go into the production of Bluebird Solar's solar PV modules. Here are some key highlights from the event:

State-of-the-Art Manufacturing Facility: Bluebird Solar's 400MW fully automated manufacturing unit is equipped with state-of-the-art machinery and equipment. The facility boasts advanced automation and quality control measures to ensure the consistent production of high-quality solar modules.

Sustainable Practices: Sustainability is a core value at Bluebird Solar. Visitors learned about the company's commitment to sustainable manufacturing practices, including the efficient use of resources, waste reduction, and recycling initiatives.

Quality Assurance: Bluebird Solar places a strong emphasis on product quality. During the plant visit, attendees had the opportunity to see the rigorous testing procedures that each solar PV module undergoes before it leaves the factory. This commitment to quality ensures the reliability and longevity of the products.

Innovation and Research: The event highlighted Bluebird Solar's investment in research and development to continuously improve solar technology. The company is dedicated to staying at the forefront of innovation and driving advancements in the solar energy sector.

Networking Opportunities: Beyond the technical aspects, the plant visit event provided a platform for networking and collaboration. EPC companies and wholesale traders had the chance to connect with industry experts and explore potential partnerships.

Bluebird Solar's manufacturing unit not only showcased the company’s commitment to excellence but also demonstrated its role as a trailblazer in the solar industry. The event left attendees inspired and informed, with a deeper appreciation for the possibilities of advancement of solar PV manufacturing technologies and production of high-quality solar PV modules.

The Most Advanced Solar Panel Manufacturing Process

  • Cutting-edge Laser Cell Cutting Machine with NDC Technology

The most advanced laser cell cutting machine, utilizing NDC technology, guarantees the utmost precision and cellular efficiency.

  • Fully Automatic Tabber and Stringer

Our fully automatic tabber and stringer are capable of handling multi bus bar cells up to 12 BB, extendable to 20 BB. They are also equipped to work with full, half, or multiple cut cells.

  • High-speed Robotic Layup and Automated Bussing

We are among the few solar panel manufacturers in India equipped with a high-speed Robotic Layup and automated bussing machine. This system has the capability to automatically align and adjust strings to precise dimensions.

  • Double EL Testing for Quality Assurance

Double EL testing guarantees the absence of micro-cracks in PV modules. This pre and post Lamination EL process helps to catch any defect and thus guarantees high-quality modules only pass through the process of manufacturing.

  • Eco Progetti's Sun Simulator

We deploy Eco Progetti's Sun Simulator, equipped with patented flash test technology for the electrical testing of cells and modules. Modules that pass this test with no microcracks or dead cells proceed to the next stage.

  • Three-stage Laminator for Top-notch Lamination Quality

The three-stage laminator, including heating, vacuum application, and cooling stages, guarantees the attainment of top-notch lamination quality.

  • Additional EL Test for Structural Integrity

An additional EL test is conducted following the lamination procedure to assess the structural integrity of the PV cell and identify any potential defects that may have arisen during the manufacturing process.

  • Hydraulic Framing Machine with Crimping Feature.

Our hydraulic framing machine with crimping feature provides automation in framing for robust frame locking.

  • Fully Automated Sealant Dispensing Machine

Our fully automated sealant dispensing machine provides durability to the solar panel.

  • Junction Box Soldering

The junction box is soldered at this stage of the manufacturing process.

  • Sun Simulation Testing for Quality Control

The sun simulation test is done using a sun simulator that replicates the light and radiation characteristics of the sun in a controlled and predictable manner using light or flash. This proves highly beneficial for acquiring IV curves and verifying outputs under standardized testing conditions.

The New Range of M10 Cell Half-Cut PV Modules

Bluebird Solar's latest offering comprises Mono-Facial and Bi-Facial solar PV modules in four distinct cell configurations, each tailored to meet specific energy requirements. Let's delve into the details of these modules:
  • 144 Cells: 540W to 550W Solar PV Modules
  • 132 Cells: 480W to 510W Solar PV Modules
  • 120 Cells: 440W to 475W Solar PV Modules
  • 108 Cells: 400W to 430W Solar PV Modules

These high-performance solar PV modules deliver an impressive power output ranging from 400W to 550W.

All these solar PV modules are ALMM, BIS & IEC certified. Ideal for large-scale solar installations, these modules maximize energy generation and efficiency. These modules are an excellent choice for projects where space constraints are a concern.

Bluebird Solar Half-Cut PV Modules have emerged as a game-changer, incorporating cutting-edge technologies to optimize the efficiency, durability, and overall performance of solar panels. Here are the remarkable features that make these modules stand out:

  1. M10 Half-Cut Cells: The M10 half-cut cells are at the heart of these PV modules, ensuring enhanced power output. By dividing each solar cell into two halves, they minimize energy losses and boost the overall efficiency of the panel. This innovation significantly enhances the module's performance, particularly in challenging environmental conditions.

  1. MBB Solar Cell Technology: Bluebird Solar has harnessed the power of Multi-Busbar (MBB) solar cell technology. MBB technology reduces resistive power losses within the module, increasing its efficiency while enhancing its overall reliability. This technology is at the forefront of the solar industry, ensuring that every ray of sunlight is converted into electricity.

  1. Highest Module Efficiency: The Bluebird Solar Half-Cut PV Modules boast one of the highest module efficiencies in the industry. Thanks to the combination of half-cut cells and MBB technology, these panels can convert more sunlight into electricity, making them ideal for both residential and commercial applications.

  1. +Ve Power Tolerance 0~+4.99Wp: These modules come with a positive power tolerance of 0~+4.99Wp. This means you can count on consistent and reliable energy production, even when conditions aren't perfect. It's a safeguard against underperformance, ensuring you get the most out of your investment.

  1. Available in Mono Facial & Bi-facial: Bluebird Solar offers these modules in both mono-facial and bi-facial configurations, giving you the flexibility to choose the best option for your specific needs. Bi-facial modules can capture sunlight from both sides, maximizing energy production in various conditions.

  1. 30 Years Performance Warranty: Bluebird Solar's confidence in the durability and performance of their modules is reflected in their First in the industry 30-year performance warranty. 

  1. Excellent Partial Shade Performance: One of the challenges with solar panels is their performance in partial shade. Bluebird Solar Half-Cut PV Modules excel in this aspect, leveraging their advanced technology to maintain efficiency even when a portion of the panel is shaded.

  1. Double EL Tested for 0% Micro Cracks: Micro-cracks can undermine the long-term reliability of solar panels. Bluebird Solar takes extra measures to ensure the structural integrity of their modules by subjecting them to double EL testing, ensuring that micro-cracks are virtually eliminated.


Bluebird Solar's launch of an extensive range of mono-facial and bi-facial solar PV modules in various cell configurations marks a significant milestone in the renewable energy sector. These modules, with their impressive power outputs, offer versatile solutions for a wide range of applications, from residential rooftops to large-scale solar farms. The plant visit event provided a rare glimpse into the company's dedication to quality, sustainability, and innovation.

As the world continues to grapple with the challenges of climate change and environmental degradation, Bluebird Solar's commitment to providing high-quality solar solutions is a beacon of hope. With their new range of solar PV modules, they are not only contributing to a greener future but also empowering individuals and businesses to take control of their energy needs while reducing their carbon footprint.

Bluebird Solar Half-Cut PV Modules represent a new era in solar panel technology. With their innovative design, MBB technology, high efficiency, and exceptional warranty, they are a top choice for those looking to harness the power of the sun for a sustainable and efficient energy future. Whether for residential or commercial use, these modules offer a reliable, long-lasting, and high-performing solution for your solar energy needs.

In a world where sustainable energy solutions are becoming increasingly vital, Bluebird Solar's mono-facial and bi-facial solar PV modules are a shining example of how innovation and dedication can drive positive change. The future of energy is undeniably solar, and Bluebird Solar is leading the way toward a brighter and more sustainable tomorrow.


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