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Roadmap for a Changed Landscape: Consolidation and Integration in Solar PV

By Greg Boutin, Riverdale Partners
December 4, 2008   |   15 Comments

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The information and views expressed in this article are those of the author and not necessarily those of RenewableEnergyWorld.com or the companies that advertise on its Web site and other publications.

15 Reader Comments
Comment
1 of 15
December 4, 2008
Nice article-
Do you really think polysilicon manufacturers will go ahead with plans for 150k tons by the end of 2010? Do you think capacity is now 50kt or is production approaching 75kt+ at end of '08? I keep checking in with prices to see when modules will drop below their trough of a few years ago. It will definitely be an interesting ride ahead in 2009.
My thoughts on the sustainable energy transition are at:
www.setenergy.org
-Dennis
Comment
2 of 15
December 5, 2008
While this helps with the cost of the modules, you need consolidation on the installation side as well to reap the same benefits.

Installlation costs are too high to ignore.
Comment
3 of 15
December 5, 2008
Thanks for dropping by, Dennis

I would indeed expect that some of the capacity additions under way will get shelved. In fact, it is happening: Suntech recently announced it would halt its capacity expansion.

However, a lot of those additions are already committed, and you can also see some manufacturers moving forward with more optimistic outlook, such as LDK which maintained its original capital spending plans for 2009, and I think we can safely assume a price drop in wafers is on the horizon. Interestingly, that in turn should feed renewed demand for panels in 2011 and beyond, and put all this new production capacity back to work.

For the industry as a whole, it is important that the polysilicon industry adjusts its plans without fully scaling back, and I think market forces are pushing them in the right direction. In the long run, the operating margins these manufacturers have recently achieved are unsustainable, and they should not operate on such assumptions. Instead, they should look at driving demand and integrating downstream, building their brand through innovation, and consolidating to achieve further economies of scale.
Comment
4 of 15
December 5, 2008
Hi Paul, you're right, installation costs often are the forgotten half (as they typically represent about half of the cost of an installed system). In my article I foresee and advocate for a consolidation at the installation level too. Utilities are also entering the play, and these dynamics will likely drive prices down.
Comment
5 of 15
December 5, 2008
Really good article
Comment
6 of 15
December 5, 2008
Vertical integration down to the installer level, whoa! Nice poetry for monopolization, that, but may as well stick with status quo if that's the future; at least existing energy technologies are "inherently" monopolistic.

Fear of fragmentation/markets certainly doesn't help America get back to its capitalist roots. Another 100-year wave of energy monopoly, with a lack of innovation coming from another Big Three, who get their bailout money at the *beginning* of the cycle--this is reason for optimism?
Comment
7 of 15
December 6, 2008
Ann,

Thanks for expressing a view which I am certain many others share.

The current energy market is far from monopolistic. In fact, it is one of the most competitive market in the world, and there is a vast number of companies and start-ups in oil, gas, coal, nuclear, and renewables, so I disagree that the current landscape is stifling the entrepreneurial spirit of America and other countries. In certain local markets however, you are right to point out that monopolistic or, more frequently, oligopolistic trends are at works. I am thinking of local utilities in particular, although those markets were opened up in many regions, and I would see the involvement of vertically-integrated solar giants as favoring even more competition in those markets.

The solar industry competes with many others to provide electricity to end users, and therefore even if there was to be only one solar company doing everything in solar, it would still compete with firms proposing the other forms of energy. In my articles, I foresee the creation of a few large "champions" with the firepower to compete in those large markets, and I do think this will be highly beneficial to solar, an industry whose costs have shown to be highly sensitive to production scale.

On the installation side, I point out that utilities could try and take control of that last mile. I think any such move will have both pros and cons, and will need to be closely monitored. But as Paul pointed out, installation costs are high and the involvement of large utilities may offer us a way to amortize such capabilities over a much wider customer base.
Lastly, on the innovation side, I noted that there would always be a myriad of ventures looking for the next technology. So we are talking about an industry with a few giants and many smaller companies, competing against other forms of energy. That doesn't make a monopoly. And no energy company in the traditional markets has yet requested any bailout.
Comment
8 of 15
December 6, 2008
Dennis, in response to your question about 2008 product capacities, I forgot to mention that in the print version there will be a graph displaying current production capacities and quoting some sources. Those sources point to total capacities of about 50,000 tons as of October, but if you have information showing those capacities are even higher, by all means please share it here.
Comment
9 of 15
December 8, 2008
Greg,

Great look at the solar industry path in light of the global "financial storm" as you call it. However, I would add one very crucial link in the traditional solar value chain perhaps being overlooked here -- where the money comes from to bring projects to market.

The power purchase agreement (PPA) model has quickly taken over 70-80% of the commercial solar market in the U.S. and that number is not likely to decrease as businesses have realized the value of working with a third-party financier. While there may be a glut of polysilicon and eventually solar modules in the market, the tax equity available to finance systems in a world of financial write-downs will be in high demand. If modules were the big shortage in 2008, I see market conditions and the ITC extension making tax equity the supply shortage of 2009. Companies with access to tax equity and good banking relationships will see more opportunities and business as customers and deals flow to them.

The market is recognizing that quality downstream companies have become a critical part of the solar value chain. Back in the days of abundant oil, companies like Exxon integrated all the way down the value chain to retail stations. Solar is the same -- upstream players are beginning to see the value in controlling the end user experience.

- Kristian Hanelt, Tioga Energy
www.tiogaenergy.com
Comment
10 of 15
December 9, 2008
Espeacially at $4. to $5. per watt still in the box, not installed.
Sounds like it would be a boon for PV.
Are you sure the PV industry can handle it.
Somebody in the PV industry has "dropped the ball" once allready and there was a "shortage in raw materials" which made PV prices to go up and those prices haven't come back down yet.
What you are suggesting, Greg, sounds to me like another increase in the price of PV modules.
Or am I reading that wrong? Are you saing that PV module prices are going to come down to $2. to $3. per watt not installed?
Or maybe what your saying is that the existing electric power infrastructure is going to raise its prices to match PV?
Ether way sounds like a boon for PV to me.
Comment
11 of 15
December 9, 2008
As manufacturers enter the installation space they must weigh the risk of alienating their existing customer base. Is the business worth becoming a competitor of their own loyal customers? The idea of vertical integration is good in a tight supply of pv. When there is an abundant pv supply the vertical integrators may have to install a good portion of their production, because their distribution chain of now slighted customers may just purchase from another manufacturer.
I do not see this happening in a big scale. Sure it can be done on a limited basis on large commercial end users, but even this may push existing large installers into the medium and small end user markets. Markets that the vertical integrators own products thrive in. These markets become increasingly complex and difficult to manage for vertical integrators. Any manufacturer or distributor that vertically integrates should be prepared to expand this integration quickly into all the market segments they service. If they want it all, they better be prepared to do it all, or lose market share trying.
Comment
12 of 15
December 9, 2008
Solar PV modules will become a commodity when supply consistently exceeds demand (duh). Product brands will become interchangeable, as will integrating and installing contractors. When traditional building contractors can purchase modules through normal wholesale channels; and make a profit installing systems; we will see a large increase in the capacity to install PV systems. Until then the PV industry will remain a primarily boutique contractor domain. High individual skill level but low level of scalability for utility class projects. Perfect for low volume, high overhead residential system installations. Not so perfect for 2GW/year ambitions.
Vertical integration will provide a method to absorb excess production into the system without significantly lowering prices and margins. The existing group of installers will always have a market but the new business will go to the efficient operations who can adapt to utility class projects. Hard to do without deep pockets. Consolidate, grow or become irrelevant.
Comment
13 of 15
January 31, 2009
Hi Greg
Very interesting article. Would like to have your comments on some other observations.
Its probably not unfair to say that PV industry is at a very early stage of development with need for significant improvement in cost structure (probably via technology breakthroughs) and stabilization of a sustainable business model. Perhaps in the first innings of the game !
History shows that vertical integration generally works for a part of the economic cycle but rarely survives a complete cycle. In Technology Industry, Dell does not make semiconductors and neither does it do end installation / servicing, and even Intel does not make PC's. In Power Equipment industry GE and Siemens make turbines but do not own power plants; Vestas and Gamesa build wind turbines but not power plants. In EPC industry Foster Wheeler & Flour build power plants but do not build equipment and neither do they own power plants. So why do you think it would be different in the PV industry ?
Particularly with respect to acquisition of downstream PV installation businesses by c-Si module makers, is there going to be any synergy if the customer prefers a Thin Film solution rather than c-Si based solution ?Finally, if the profit margin and Return on Capital in the installation business is significantly lower than the component business for Sunpower, what do you think would be the rationale for this downstream integration ?
Regards
Comment
14 of 15
February 18, 2009
Hi Sunil,

Thanks for the thoughtful comments. A lot of those have to do with a prediction for a "stabilized" solar playground, which as you point is not the case at present and certainly won't be for some time to come. I can't agree that most of that will come from technological breakthrough, which is always possible but has not shown to be the top industry driver in "history" as you like to call it. Rather, economies of scale have been, and that's why silicon panels are still dominant. But this is a sidepoint, since I concur with the idea that the field is still in flux, and talking about some end state at this stage appears futile and premature.

Rather, I claim that we are going to see consolidation in the short to medium term, and that is going to include a good level of vertical integration, driven by the need to secure access to market on the one end, and cash injection on the other. If you take a closer look at my article, you will see that I place the last mile distribution in a somewhat special category, as I anticipate utilities to step into that space, and the recent months have confirmed that trend (see PG&E move). Most of your arguments hinges around the difficulty of marrying distribution (and project integration) with manufacturing, which is a valid point and one I do not contest. There will be some companies playing in both fields, such as SolarWorld AG which has been doing very well, and there will be others, integrated horizontally. I anticipate manufacturing, e.g. ingot/wafer/modules, to be further integrated in the short run due to the financial capabilities acquired by those manufacturers, and I believe it makes sense from a cost (cutting internal margins) branding and market development perspective. Note that a number of industries are still vertically-integrated, e.g. tires, oil, and this is often driven by the need and the ability of the upstream part of the business to control the downstream part for market access. Sounds like solar.
Comment
15 of 15
March 19, 2009
The full article that appeared in the magazine is now available at http://www.renewableenergyworld.com/rea/news/article/2009/01/roadmap-for-a-changed-landscape-consolidation-and-integration-in-the-solar-pv-business-54348
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