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Intersolar Day 1: The Need to Cut Capital Costs and Regain Stability

Steve Leone, Associate Editor, RenewableEnergyWorld.com
July 09, 2012  |  6 Comments

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Tom Cheyney of Impress Labs spent little time stating the obvious — the solar industry has undergone a titanic shift in the past year. And the rest of the presenters who kicked off the first day of Intersolar North America in San Francisco detailed what the industry needs to do to get back on a sustainable course.

On Monday morning, Cheyney recounted how Ben Bierman, a former executive at Solyndra, painted a bullish picture of his company’s plans during last year’s Intersolar North America gathering. Just 12 months ago, Bierman told those in attendance that his company was meeting its cost goals and remained busy ramping up production.

Of course, a bit more than a month later, the company announced plans to file for bankruptcy, and the failed manufacturer soon became the focal point of angst against President Obama’s clean energy agenda. But Cheyney and many in the industry see Solyndra as more than just political fodder. “There’s a word for it,” said Cheyney. “It’s called carnage. And that goes for any industry with growth like solar.”

Despite the difficulties the industry has faced in the past year — namely overcapacity and scaled-back subsidies in traditionally strong markets — there are signs of clearer skies ahead. To get there, though, there needs to be both a shift in attitude and a re-examination of market mechanisms, argued two of the conference’s first presenters — Chase Weir of Distributed Sun and Sanjay Shrestha of Lazard Capital.

Shrestha had a warning for those in the industry, and it’s something some may not want to hear. He said companies need to move past the subsidy-chasing nature of their business and work to build a global solar industry that can thrive without subsidies. The market will find balance, he said, and when it does it will re-emerge under a new era, one with much smaller profit margins than we saw a few years ago. But it’ll be an industry capable to accelerating its growth to mainstream adoption.

Weir detailed the status of the industry today, how it is starting to change and how it will look by 2015. Right now, the industry is working on new financial models, especially in the U.S., where the loss of the 1603 Treasury Department grant has taken away a key financial tool. Those operating in the U.S. are also looking to cut into soft costs while building new business and policy models. By 2015, the industry will see a much lower cost of capital and a lower cost per watt. There will also be an exit from private markets and into public equities.

The biggest shift, he says, needs to come in the cost of capital, which on an installed basis equals about $1 a watt, making it even more expensive than the cost of panels. In addition to more access to capital, the global industry will also include fewer major manufacturers. We’ve already seen this in the past year across many markets, and the shakeout is likely to continue for module makers across the globe, from European manufacturers to Tier 3 Chinese companies.

American thin-film manufacturers have faced a recent run of bad news with the closing of Abound Solar and GE followed with an announcement that it will delay the opening of its massive thin-film plant by 18 months. Joe Berwind of AEI Consulting questioned whether the company could bounce back from such a long absence and emerge as a player in the struggling thin-film field.

But even with the challenges ahead, Cheyney stressed that the industry needs to remember how far its come, globally and here in the U.S. where the American market continues to surge. "The future is in terrawatts," he said. "That's where we're going with this. It's about keeping our eyes on the prize."

The session was part of the SEMI North American PV Fab Managers Forum.

Lead image: Money Puzzle via Shutterstock.

6 Comments

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william payne
william payne
July 10, 2012
Hi Bill, Jason A. Marks commented on your link.

Jason wrote: "Schott Solar's closing, like the troubles facing other US solar manufacturing plants (eg, Solyndra) have much more to do with broader US trade and manufacturing dynamics than they have to do with solar or renewable energy factors. Solar and other forms of renewable energy are alive and well in New Mexico and the U.S. We've got about 170 MW of solar generation in operation today in New Mexico, producing enough electricity to power 150,000 homes during daylight hours. (NM was ranked #1 nationally in solar electric generating watts installed per capita for 2011!!) But, as solar panels have become a low-cost commodity, we have found that US solar panel manufacturing no better at matching the low prices of Chinese manufacturing than we are in other areas of electronics manufacturing (go to Wallmart or Best Buy and try to find home electronics made in the USA). Politicos like Richardson and Obama tried to overcome Chinese labor cost advantages through subsidies like Schott and Solyndra received. This was theoretically possible, because even though Chinese labor costs per hour are much lower, US workers are actually a lot more productive. But what happened was that the Chinese government gave its solar industry their own subsidies, in most cases a lot more than Washington and Santa Fe were doling out. So in the end, plants like Schott were undercut by the govt-supported Chinese panel manufacturers."
http://www.prosefights.org/nmgco/intervene/hearing/hearing#fitzpatrick
Ronald Barrett, Pres. EWEI
Ronald Barrett, Pres. EWEI
July 10, 2012
Interesting that the so called Financial/Banking sector expects twice the rate of return over the industry. To be bluntly honest:The bankers are way too greedy! This greed hurts industry.

Our small RD&T solar+wind company is currently passing from R&D into a manufacturing mode with significant IP (IP to us means Intellectual Property;not stock offering)at our disposal. We have "zero debt," not asked for, or received any type of grant, and have more money than we began with and are 100% self financed. We intend to stay that way.

Going into our third year we can see however the drawback to this approach is it takes a lot more time to get into production. To off-set this negative, we have sought to line up "innovations" that we intend with USPTO protection to meter-out so as to establish and then maintain a good market position once in production. So we treat our "IP" as a in-house product line.

IP also means we need to factor into our product development a continuum of changes right into production, sales, technical support, warranty and change out of product at a later date. Clearly the current (failed) PV companies did not do this.

In a year or two we trust we will be in full production, but not in the way once thought of. Our production line is to be on-going changing out-put product manufacturing. We intend to take back obsolete systems for recycle and to clear the market of out-of-date systems.

The above has taken hard dedicated work and many innovations.

Looking forward to hearing others approach on Solar up-starts

Chief Engineer RD&T
ANONYMOUS
July 10, 2012
It seems that the hardest shift in the "new normal" for solar financiers is the adjustment to more reasonable returns for a 20-30 year asset. For example, the orthodox energy capital investing in PV are seemingly content with < 8% returns and lower NPVs, while the more aggressive "banking sector" investors still contend that 10%-15% is the bare minimum and a 2-4 year payback is only sensible.

Tangentially; this seems to be reflective of the US economy as a whole, Meaning, returns on investment, a perceptions of acceptable growth have come down to earth for everyone except those on Wall St.
ward hansen
ward hansen
July 10, 2012
In RE: ANONY July 10th Installing at an average of $1.00/kW is possible. Law of large numbers and economies of scale have always applied in construction, even solar builds. Inverters are the one remaining element that has not found a lower price point in my experience. Wonder why given all of the other BOS corrections. Lastly it is always hard to wein ourselves off of the DOLE. Blaming Obama for poor business decisions by some in the industry has no merit. Not that I support many of his views I do on solar as at least he tried to create a market stimulus that was good for the economy and green theme. It was never intended to last forever. Let's take what we like and leave the rest.
ANONYMOUS
July 10, 2012
I find its amazingly nieve to think installers are going to get installed costs down to $1.00 a watt. In the US installers don't work for 3 cents an hour. Anybody who suggests that is a realistic cost does not know construction or has actually installed a system themselves to see or know what's involved in an installation. Work hard and innovate you suggest? Any installer knows its more expensive to install a small system vs. a larger system and that dynamic won't change.
ANONYMOUS
July 9, 2012
It's refreshing to hear some of those involved in the solar industry starting to acknowledge some cold, hard economic realities facing them. Things like they need to quit basing their business models on large subsidies, that they need to be more realistic in expectations of profit margins, and that solar capital costs and LCOE must still come way down to be competitive in the current energy market. Mr. Cheyney made a few good points, but I wish he would refrain from using the term 'sustainable' to describe what the solar industry should strive for. The free market is the most efficient and proven mechanism for guiding business decisions. Why would any investor risk their money on a company that only seeks to 'sustain' itself? As a company official, his foremost goal should be to develop and market products that are in demand and can be sold for a reasonable profit. I heartily agree with Mr. Cheyney's comments in the last paragraph. The US solar industry has made great technological progress in recent years, and the ability to develop technology is still one of our country's greatest assets. Eventually, solar will be truly cost competitive with other energy sources. But we should get there using good old fashioned hard work and innovation, rather than relying on artificial means like large taxpayer subsidies and import tariffs. All the cash subsidies in the world cannot compete with the power of technological innovation.

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Steve Leone

Steve Leone

Steve Leone has been a journalist for more than 15 years and has worked for news organizations in Rhode Island, Maine, New Hampshire, Virginia and California.
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