EVA POE EPE Solar Film Extrusion Line

GWELL Machinery Company Profile and Product Introduction

Company Profile

GWELL Machinery Co., Ltd. is a national high-tech enterprise specializing in the manufacture of flat forming equipment for polymer materials. Over the past decade, GWELL has experienced rapid development and now boasts three manufacturing bases and one office in Shanghai:

· Manufacturing Bases: Located in Taicang City, Suzhou; Chongchuan District, Nantong; and Dafeng District, Yancheng.

· Equipment: Equipped with over 300 processing machines, including gantry machining centers, precision machining centers, laser forming machines, and CNC lathes.

· Production Capacity: Capable of producing 1,000 sets of flat forming equipment annually.

· Market Reach: Products are exported to the USA, Germany, Japan, South Korea, Russia, Spain, Turkey, Indonesia, India, South America, and other countries and regions.

EVA/POE/EPE Film Production Line

GWELL's EVA/POE/EPE photovoltaic film production line holds a 70-80% market share globally. The company has produced hundreds of photovoltaic EVA film production lines, forming a mature production system, and providing comprehensive services from raw material procurement, formula consultation, auxiliary equipment matching, to process debugging and training.

Market Leadership

GWELL maintains an over 80% market share in the EVA photovoltaic film equipment sector. The equipment has undergone thousands of designs and optimizations, achieving high product yield and automation levels widely recognized by leading companies. Leveraging its scale and resource advantages, GWELL excels not only in equipment development but also has deep insights into upstream suppliers and downstream customers in the photovoltaic film industry.

Equipment Features and Advantages

Extrusion System

· High Torque Gearbox: Provides strong power support, ensuring efficient and stable extrusion.

· Efficient Screw Design: Optimizes the plasticization process, ensuring uniform melting of materials, particularly suitable for temperature-sensitive EVA materials.

· Constant Temperature Circulating Water Cooling System: Ensures that the temperature difference between the screw and the barrel is ±1°C, addressing EVA plasticization and non-crosslinking issues.

Screen Changer

· Plate Type Screen Changer: Efficiently filters impurities, reduces downtime and material waste, improves production continuity and efficiency.

Melt Pump

· High Precision Pressure Control: Ensures that the pressure fluctuation after the pump is ±0.1MPa, ensuring uniform film thickness.

· Pressure Detection Sensors: Quick response and accurate detection, ensuring consistent longitudinal thickness.

T-Die

· Manual and Automatic T-Die: Selected according to demand, ensuring uniformity and accuracy of the film's transverse edges.

Calender

· High-Strength Rollers: Temperature fluctuation precision ≤±1 degree, ensuring film quality.

· Double-Sided Embossing: Prevents film from sticking to rollers, improving surface quality.

Cooling System

· Special Cooling Rollers and Stress Relief Bed: Ensures smooth film operation and full forming, keeping shrinkage below 3%.

· Cooling Bracket: Precisely designed to effectively cool the film, preventing warping or shrinkage.

Thickness Scanner

· Real-Time Feedback Adjustment: Used in conjunction with the automatic T-Die to reduce labor costs and ensure consistent product thickness.

Cutter

· High Precision Cutting: Ensures neat film cutting without burrs.

Haul-Off System

· High-Wear-Resistant Nitrile Rubber Rollers: Ensures stable traction and high surface quality.

· Independent Servo Control: Ensures stable and reliable traction process.

Winder

· Micro Tension Control: Ensures smooth side winding, reducing internal stress.

· Automatic Relaxation Cutting: Improves operational efficiency, reduces material waste.

Automated Control System

· PLC Control System: Achieves fully automated line control, easy to operate, saves labor.

· Online Quality Monitoring System: Ensures consistent quality for each batch of products.

Advantages of the Three-Layer Co-Extrusion Structure

Benefits of the Three-Layer Co-Extrusion Structure

· Performance Optimization: Combines the advantages of EVA and POE, fully exploiting each material's properties for maximum performance.

· Structural Stability: The middle POE layer provides excellent weather resistance and UV resistance, while the EVA layers on both sides offer high transparency and adhesion, ensuring the overall stability and durability of the film.

· Cost Saving: Through a reasonable combination of materials, the use of high-cost materials is reduced, lowering overall production costs.

Advantages of EVA

· Better Adhesion: EVA has better adhesion than POE, closely bonding various interfaces, ensuring reliable encapsulation of components.

· High Transparency: The EVA layer offers excellent optical performance, suitable for solar cell encapsulation and other applications.

· Low Cost: EVA is cheaper than POE, and using EVA as the outer layer can effectively reduce production costs while maintaining high performance.

Advantages of POE

· Excellent Weather Resistance: POE has good high and low-temperature resistance, remaining stable in extreme environments.

· UV Aging Resistance: POE's molecular structure lacks unsaturated double bonds, giving it excellent UV aging resistance, extending product lifespan.

· Low Water Vapor Transmission Rate: POE ensures the safety and long-term stability of encapsulated components in high humidity environments.

Overall Advantages of EPE Film

· Combination of High Performance and Low Cost: The EVA layers provide excellent adhesion and transparency, while the POE middle layer offers weather resistance and UV resistance, achieving a balance of high performance and low cost.

· Versatility: Suitable for solar cell encapsulation, building materials, and various other fields, meeting diverse application needs.

· Durability and Reliability: Combining the advantages of EVA and POE, EPE film offers good durability and reliability, maintaining stable performance in high temperature, high humidity, and strong UV environments.

Equipment Challenges and Innovations

Temperature Control Challenges

· High Precision Temperature Control: For temperature-sensitive EVA materials, special screw design and constant temperature circulating water cooling system ensure complete plasticization without local over-plasticization.

Shrinkage Control Challenges

· Stress Relief Device: Effectively eliminates residual stress generated during film production, controlling shrinkage within 2%, improving product stability and yield.

Automated Operation

· PLC Control System: Achieves fully automated line operation, reducing labor costs and improving production efficiency.

· Efficient Filtering System: Optimized screen changer design reduces material waste, improves production continuity and efficiency.

Market Layout

· Global Market Layout: Equipment is exported to multiple countries, achieving high market share and stable, reliable performance.

Detailed Technical Configuration

Electrical Supply

· Voltage: 380V /3P

· Frequency: 50Hz

· Voltage Fluctuation: ≤±15%

· Frequency Fluctuation: ±1.5Hz

Cooling Water Supply

· Maximum Water Supply Temperature: 7-20℃

· Water Supply Pressure: 4-6bar

· Pressure Fluctuation: ±0.5bar

· Average Return Water Pressure: 1.5bar

· Circulating Water Volume: 35-40 m³/h

Compressed Air Supply

· Clean Air Source: Free of oil, water, and dust

· Supply Air Pressure: ≧7bar

· Pressure Fluctuation: ±1%

· Air Volume: 1 m³/h

Main Equipment Parameters

· Extruder: GWS180/35 single screw extruder, maximum extrusion capacity of 350-550kg.

· Maximum Product Width: Determined by mold and roller width.

· Product Thickness: 0.4-1mm.

· Mechanical Design Line Speed: 18m/min (maximum), EVA normal production speed 12-15m/min, POE 8-12m/min.

Production Line Components

GWS180/35 Single Screw Extruder (2 units)

Equipped with steel platform and water tank, nitrided + chrome-plated screw, material 38CrMoAlA, screw diameter 180mm, maximum speed 30 rpm, L/D ratio 35:1, total heating power about 60KW.

Custom Plate Type Screen Changer (2 sets)

 Includes hydraulic station.

Melt Metering Pump (2 sets)

 With water cooling and control system.

Connecting Flow Channel (2 sets)

Complete connection of extruder, screen changer, melt metering pump, and mold.

 Distributor (1 set)

Reasonable design, flow channel chrome-plated, mold lip width as per customer requirement.

Casting Film Machine (1 unit)

Patented roller design, internal flow channel design, high cooling efficiency.

Cooling Rack (1 set)

Aluminum roller specifications Φ100×3000mm, hardened treatment.

Cooling Roller Set (1 unit)

Three-roller water cooling system, roller specifications Ф570mm×3000mm.

 Edge Trimming and Slitting Device (1 set)

Rotary knife cutting, adjustable edge trimming.

Static Eliminator (3 sets)

 Double-sided, installed on cooling rack and winding machine.

 Haul-off Machine (1 set)

Specifications Ф200×3000mm, equipped with Inovance servo motor.

Friction Center Winder (2 units)

Automatic cutting and winding, winding control system.

Full Set Electrical Control System (1 set)

GWELL sheet and film extrusion production line control system software V1.0.

Edge material haul-off and conveying device. (1 unit)

Includes edge material haul-off and conveying device.

Vacuum Feeder (2 units)

Feeding capacity 1000kg/h.

EVA/POE Film lines Performance Features

· Extrusion Section Design: Large diameter single screw, circulating water cooling, solves EVA non-plasticization and non-crosslinking issues.

· Roller Section: Double-sided embossing, solves film sticking to roller issues, customizable embossing patterns.

· Cooling Section: Cooling rollers and stress relief bed, ensures shrinkage below 3%.

· Control System: PLC full automatic control, integrated HMI touch screen.

· Quality Monitoring: Online quality monitoring control system.

· Winding System: Micro tension winder, line speed up to 18m/min, minimal tension variation.

Photovoltaic Film Applications

Transparent and White EVA Film

Single glass modules typically use conventional transparent EVA film and white film for front and back encapsulation. White EVA film has high reflectivity, effectively increasing the reflection of incident light between cell gaps and the transmittance light of the module, thereby improving module efficiency by 1W-3W.

POE Film

Double glass modules and N-type cells experience severe PID attenuation issues. Replacing EVA resin with POE resin, which has better water resistance, weather resistance, and transmittance, leads to the development of POE film.

Multilayer Co-extruded POE Film (EPE Film, EVA/POE/EVA Structure)

Due to the high cost of POE resin controlled by a few foreign petrochemical companies, and the generation of many bubbles during lamination, resulting in high defect rates and extended lamination times, multilayer co-extruded POE film was developed. This film combines POE’s PID resistance with EVA’s high yield and lamination efficiency, reducing POE usage and achieving cost reduction and efficiency improvement. It is currently being introduced and mass-produced by first-tier module manufacturers.

Manufacturing Challenges and Innovations of EVA Photovoltaic Film

EVA’s Sensitivity to Temperature

EVA resin is highly sensitive to temperature. Precise temperature control directly affects the quality of the final product. GWELL Machinery designed a special screw for EVA to ensure complete plasticization without local overheating. Continuous optimization has now increased the production line speed to 16m/min, making it competitive with German equipment.

Strict Control of Winding Tension on EVA

The internal stress of EVA photovoltaic film significantly impacts product quality. GWELL Machinery’s winder strictly controls the product tension within 20N, ensuring product yield. Additionally, GWELL’s fully automatic winder minimizes waste.

Single and Double Machine Equipment for EVA, POE, and EPE

GWELL Machinery’s single machine equipment can produce EVA and POE films, while double machine equipment can produce EPE films. Double machine equipment is mature and widely used in the domestic market, while markets like India are transitioning from single to double machine equipment.

Service and Support

GWELL provides comprehensive services from raw material procurement, formula consultation, auxiliary equipment matching, to process debugging and training. During installation and debugging, technical personnel are dispatched for guidance to ensure smooth operation.

Production Efficiency and Service Commitment

· Annual Output: The EVA dual-machine 180 main machine photovoltaic film extrusion line has an annual output of 1GW, with pure POE output of about 0.8GW.

· Service Commitment: Technical personnel are provided for installation guidance and equipment debugging, with complete spare parts.

Future Development Direction

GWELL will continue to strengthen research and development in new energy, new materials, and energy conservation and environmental protection industries, maintaining technological leadership and providing efficient and stable photovoltaic film production solutions for global customers.

Customer Cases

· Case 1: GWELL Machinery’s EVA/POE photovoltaic film production line has been successfully applied to a major solar panel manufacturer in Germany, improving their production efficiency and product quality. Customers praised the equipment's reliability and advanced features, significantly enhancing market competitiveness.

· Case 2: In Japan, a leading solar company adopted GWELL’s POE film production line to address PID attenuation issues in their double glass modules. GWELL provided comprehensive services from equipment selection to installation and debugging, helping the customer complete the production line construction smoothly and achieve good market response.

· Case 3: In South Korea, a major photovoltaic module manufacturer chose GWELL’s EVA film production line to enhance production efficiency and ensure high product quality. With GWELL’s technical support and training, the company successfully optimized its production process, significantly reducing the defect rate and improving product consistency and market competitiveness.

· Case 4: An emerging solar energy company in India adopted GWELL’s multilayer co-extruded POE film production line to meet the demand for high-efficiency solar panels. GWELL provided comprehensive technical solutions, helping the customer overcome various challenges in the production process, significantly improving the production line’s efficiency and product performance.

Customer Directory

1. ATS

2. Better

3. HIUV Materials Technology

4. 3M Xiangbang

5. Tony Tech

6. Lushan New Materials

7. Crown Material

8. Cybrid

9. Sveck New Materials

10. Exciton

11. STR Holdings, Inc.

12. WAAREE

13. TPI

14. Alishan Green Energy Pvt Ltd.

15. Navitas Solar

Conclusion

GWELL Machinery Co., Ltd. has secured a leading position in the photovoltaic film production industry with its professional technical team, advanced production equipment, and comprehensive service system. The company will continue to be customer-oriented, constantly optimizing and improving product and service quality, and striving to make greater contributions to the development and progress of the global photovoltaic industry. GWELL’s EVA/POE/EPE film equipment, through advanced extrusion and co-extrusion processes, efficient automated control systems, and optimized structural design, leads the industry in performance, efficiency, and quality. The three-layer co-extrusion structure fully utilizes the advantages of EVA and POE, ensuring high performance while maximizing cost efficiency. Through this innovative design and efficient production process, GWELL provides customers with efficient, reliable, and energy-saving production solutions, meeting the market’s demand for high-quality, cost-effective products.