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Solar PV Profit's Last Stand

Paula Mints, SPV Market Research/Strategies Unlimited
March 20, 2013  |  39 Comments

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Globally, average module prices (ASPs) decreased by 42 percent in 2012 from a global ASP of $1.37/Wp in 2011 to $0.79/Wp in 2012. In early 2013, ASPs have already decreased by 18 percent to $0.65/Wp with inventory averages ~$-.58/Wp. Many will proclaim this as progress. Some will say that the ends justify the means. A few will devote a brief paragraph to the losses and failures of manufacturers before going on to write of the hugely successful 2013 to come. Some manufacturers may join the chorus lest they be drowned out by drumbeats broadcasting success.

Simply put, a 42 percent decrease in price in one year is not progress by any logical assessment of it, nor is it representative of true learning. The PV industry leapt off of the learning curve several years ago caught up in pricing for share that has turned into a nightmare.  Should prices decrease by 42 percent in 2013 the ASP will decrease to $0.46/Wp.  Logically it would be difficult to make an argument that prices this low relate in any meaningful way to cost — yet, some will make this argument. Figure 1 presents PV module ASPs from 1992 through 2012, including the average price for inventory in 2012.

Market theories of pricing are useful to provide a framework for the behavior exhibited by participants in a market. Unfortunately, these theories are often used to justify opinion at the same time ignoring details such as the availability of substitutes, the macro and micro economic environment in which the behavior exists as well as the constraints in which the market operates.  In the case of PV, electricity is viewed as a basic need and so utilities and others take seriously the need to provide it at as low a cost to the consumer as possible.

Every entity along the energy value chain will try and maximize self-interest, including the need for positive margins and profits.  Pitting self-interest against self-interest typically reveals passionate explanations as to why each side has merit over the other.  Arguments for continued low cell/module pricing are shored up by saying that the point is to get more PV installed — basically, the ends justify the means.  Though the evidence is now quite clear that current PV module prices do not support continued R&D or positive margins the facts become blurry in the face of high deployment figures.  An industry wherein only one side or another makes a profit at any given time cannot be described as healthy.  Figure 2 offers data on PV manufacturer revenues and losses in 2012. 

There Are No Normal Markets, Only Theories About Normal Markets

Forgetting the normal tension between buyers and sellers in any market — simply put, buyers seek the lowest price while sellers seek the highest price with the assumption that the equilibrium price is somewhere in the middle — this assumption assumes a normal market with pull that is not legislated and that does not require an instrument (incentive) of some type to exist.  The U.S. RPS model is a legislative instrument and unfunded an mandate requiring utilities to install a certain level of renewables by a certain time.  A market where incentives and legislation are necessary to stimulate purchase is not mature. Nonetheless, the basic concept applies; installers and system integrators seek to buy modules at the lowest price in order to maximize value.  PV manufacturers, however, are discouraged from seeking the highest price by set expectations that progress has been made, by high levels of module inventory and by the availability of substitutes — all of which set up a painfully steep slope of downward pricing pressure. 

Referring to Figure 1, in 2004 prices for PV modules began increasing because the highly profitable FiT model stimulated demand and because of an increase in the price of polysilicon starting material.  High demand stimulated by the FiT model was by far the most significant reason that module prices increased during this brief period.  During these brief profitable days vertical integration was considered and occasionally acted upon but not seen as the last chance for PV manufacturers clinging to the last vestiges of margin.  Nowadays vertical integration is less a strategic choice than it is a last stand against potential failure.   

Figure 3 offers four charts that follow PV industry growth from 1975 through 2012.  From 1975 through 1982 the industry was in period of high incentives and high government/utility demonstration projects, prices declined by a CAGR of -18 percent while demand increased by a CAGR of 88 percent.  From 1982 through 1992 PV industry growth was slower, at a CAGR of 22 percent, while price declines slowed to a CAGR of -10 percent. In 1992, the industry began to move into a period of moderate incentives.  In particular, California, Japan and Germany enacted rebate programs aimed at stimulating domestic demand.  Demand growth for the period increased to a CAGR of 25 percent, while price declines, despite increased demand, slowed to a CAGR of -6 percent. 

The final period observed in Figure 3, 2002-2012, saw a high incentive environment (FiTs) drive the industry to gigawatt levels of deployment and a CAGR of 48 percent, while prices, viewed through the lens of compound annual declines, decreased by -13 percent.  This decline obfuscates significant annual declines of -27 percent in 2009, -40 percent in 2011 and -42 percent in 2012. The compound annual rate by which prices declined during the 38 year period observed in Figure 3 is -11 percent. The 2002-2012 period also saw overheated markets collapse, the beginning of tender bidding on projects (this tends to hold prices and PPA rates down).  To be fair, it also saw the markets in Latin America and Africa begin to emerge while the low prices helped to encourage China to make significant progress in domestic installations.

The PV industry has a long history of aggressive pricing (by all regions at one time or another).  This pricing strategy is also referred to as pricing for entry or defensive pricing.  In any industry with significant downward price pressure the control over price setting is almost always out of the hands of the manufacturer. 

A Brave Few Make a Likely Futile Stand

A few PV cell/module manufacturers have stalled price reductions and in several cases are trying to increase prices by $0.02/Wp to $0.05/Wp.  Given current high levels of inventories (in some cases including modules that were bought for failed projects) manufacturers are competing with their own modules.  Some installers/system integrators agree that current price levels are not healthy for manufacturers.  Nonetheless most buyers will hold the line against price increases in what has historically been a market where buyers control the price function.

History is rife with brave and often futile stands with the rightness of the stand identified with the passing of time or political fashion.  Likely relatives of General George Armstrong Custer and his men thought poorly of the Indians at the Battle of Big Horn where Custer, essentially, allowed his troops to be surrounded by several tribes and thousands of Indians and dispensed with (to put it mildly).  From the Indian’s point of view, having suffered through broken treaty after broken treaty, it was a stunning but ultimately short lived victory.  The 1836 battle of the Alamo in Texas could either be a land grab or fight for independence from Mexico depending on which historian’s account you read.  The history of the world is filled with people fighting bravely on one side or another of a cause held dear by someone.  Bringing this back to PV, the current fight against whether or not PV module prices should or can increase is not new (just as aggressive pricing strategies are not new).  The PV industry is simply too big now to continue losing money on such a wide and public basis and to pretend that low to negative margins and significant losses are okay. 

For the industry to take its place as a mainstream energy choice it needs to be true to its quality roots, get back to the basics of pursuing incremental improvements towards higher efficiency and lower costs so that it can compete with substitutes as an energy choice — and do so profitably.  In the future the energy business is likely to be one of customer choice in which owning the means of renewable energy production is viewed as a hedge against escalating energy prices and a deteriorating environment.  Energy conservation will be the matter-of-fact way in which people live their lives. For PV to survive it continued innovation is required — and though ideas are free, innovation and manufacturing cost money.  2013 should be a year of increased deployment along with positive margins and net incomes.

39 Comments

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Dennis Heidner
Dennis Heidner
March 24, 2013
My comments about panels as commodity -- were generic. I am fine on panels. I also used the tax credits previously for my installation. The argument for "Green" bank like KfW instead of tax credit - is the observation that a significant number of residential customers are now choosing to lease their installation. That means access to funds for solar is an issue - for many residential customers.
John Nistler
John Nistler
March 24, 2013
I personally prefer extension of tax credits. Allow individuals the same tax credits received by business and utilities and the overall residential market would increase substantially. Tax credits are difficult to pull when it affects a majority of voters.

If you do have to replace one panel in a string, you might want to consider replacing that panel with a PVac system. Most inverters can deal with string to string imbalance.
Dennis Heidner
Dennis Heidner
March 24, 2013
John, I agree absolutely!

But for the existing installations and with the failure of some manufacturers and future consolidation of others, there is no guarantee that you will be able to buy equivalent modules. And with fast turns by the module makers - you may not even be able to buy a replacement module that you just received a few weeks before.

There are solutions that can solve the problem:

1) we could force manufactures to build inter-changable modules -- truly commodity items -- that actually slows the innovation down and doesn't move forward.

2) adopt "Tygo" like mppt modules on all solar modules, make the device programmable so it can emulate IV curves... much like printers often emulate laserjet/epson printers.

3) use one inverter/solar module (enphase like devices)which makes the string a lower voltage bus. This of course doesn't work as well for the VERY large solar projects. (Yes, I know there are some large projects made with enphase inverters).

Back to Paula original blog theme Solar PV's profit last stand. These have been good discussions of the problems - and as she pointed out.

"For the industry to take its place as a mainstream energy choice it needs to be true to its quality roots, get back to the basics of pursuing incremental improvements towards higher efficiency and lower costs so that it can compete with substitutes as an energy choice — and do so profitably."

I don't believe we can expect the manufacturers to be funding the industry, nor do I believe that the solution is entirely fixed by magically shrinking select portions of the BOS. I do not know the solution, if I did - I would be quite wealthy.

Over the year though, I have become increasingly convinced that the solution isn't a German style nation wide FiT either. But more likely changes to funding and Fannie Mae. I like a "Green" bank or the equivalent of KfW more and more....
John Nistler
John Nistler
March 24, 2013
This is why its important to use the same basic building block independent of size of project or how old the project is. Its true that trying to install a different size panel into a string is not feasible. This is also why we took a design approach that concentrates on each panel being a system by itself. Install a PVac500 watt today and in three years, you can replace that panel system with a larger one, such as a PVac550 or PVac600. But this approach specifically requires top down understanding that to be competitive you must plan on your product being competitive with little project engineering requirements independent of size of project.

The technology has continued to progress, yet management of many of the PV companies, installers, etc, did not keep on top of the newest and best approaches falling into the trap of "Not invented here" or "building a personal power pyramid". Ignore the customer's issues and you soon will be without customers!

I agree that any installer who does not partner with a systems integrator who provides them with real solutions but instead picks up what ever is cheapest at the time, will eventually go out of business, aka, treat everything you do as a commodity and soon anyone can replace you.

So look at that complicated racking system that you are installing. How can you compete with the installer who uses a system that just screws into place independent of it being a cement, metal or wood roof or an iron frame. Look at the installer who is independent of string concerns and mismatching of panels or shadow effects, and who will end up being the winner when the dust settles?

Poor selection of components is like going to a gun fight with a knife. But gunfighters did not make their own guns, why do installers think they can put their own systems together?
Dennis Heidner
Dennis Heidner
March 24, 2013
I agree you need to keep improving the product and its efficiency. But not in a weekly competition. Japan's electronic and auto industries are good examples of that. Lots of small continuous improvements in the process, then perhaps twice a year bumps in the product. But it seemed that sometimes there was a race on to compete and have the best performing product at the trade show. The problem being of course is that there are/were perhaps a hundred solar trade shows around the world.

And we (non-manufacturers) expected our favorite brand to always be on the top. That was unfair expectations on our part.

Solar panels are not commodities (like an wall outlet), even though we like to treat them as such. Racking system, inverter and system design may dependent on the module choice. Does anyone know of a house that was dependent on the choice of wall outlet brands? Certainly if you were buying hundreds or thousands of panels for projects - they became a commodity for those projects. But they still are not necessarily inter-changeable between projects of different ages and locations. I can certainly take a gallon/liter of gasoline (a commodity) and use it on many different vehicles. But take a brand X solar module and try replacing a brand Y module in a string array -- and you better have done your homework and some calculations (then say a few prayers). Modules are not commodities.

Expecting modules to be treated as commodities at very low prices will does not serve the industry. Funding for projects needs to come from VC or banks that want to be assured that they will see their investment repaid. The investors have specialist that follow the solar industry - and they understand the long term support issues and need to replace failed products. They are not as likely to fund projects if they don't think the manufacturer will be around to support the products.
John Nistler
John Nistler
March 23, 2013
Dennis, the other side of that is you need to also continue to improve the performance of your product while reducing your manufacturing costs. Look at Schott Solar, BP Solar, Yingli and others who stayed at 14.5% efficiency when prices were good and made no effort to improve their product. They now cry that price eroded too quickly. Sorry, any technical business needs to understand cost and performance are both factors that must be met to maintain income.

And review is absolutely necessary, if Groups like Wurth have decided they can not longer compete economically in the install area, this is a valid business decision. As PVac systems become easier to install, large engineering overheads can no longer be justified. A good integrator for example will include optical and electronic optimization for DC and AC power production with the intent to simplify overall install process.
Dennis Heidner
Dennis Heidner
March 23, 2013
I think it would really be interesting to compare the BOS costs from France, Germany, Italy, Spain and Greece with the US. That might give a better insight as why German BOS costs are reported as low as they are.
Dennis Heidner
Dennis Heidner
March 23, 2013
Yes, I do think data was missed. In fact the first draft report was revised by the authors at LBNL when they discovered the install reported by the German installers were under reported by about 30 hours. I think there are still missing hours. And yes, while I Germany I collected info and have been working on writing a response back to the LBNL researchers.

But even if the BOS costs in the US are not ever as low as Germany, that doesn't mean it isn't a good deal, or that the market will not grow. It will. I just believe we are focusing on trying to squeeze a few more cents out of the wrong places.

On if the items I've been following for the last six months now are a few of the German installers - some are shutting down to refocus on other areas (Wurth). There have been some small installers looking for other business opportunities. A year ago there were some pretty large demonstrations in Berlin protesting changes in the FiT because they expected major slow downs. At the EU-PVSEC conference/show in Frankfurt last October -- I did not see a lot of European module producers, or people from their distribution chains. I was honestly surprised that there wasn't a larger presence. However the Chinese were their showing their products. And talking to the German installers there and later in Freiburg -- I sensed a very definite concern. In April 2012 the FiT was at 90% retail. It drops every month. So it will be later this year that we start to see the drop in the German install numbers. Take a look at them again in the Q3 of 2013.

Germany is also trying to promote solar thermal, it has also been taking a heavy beating. And they are TRYING to rollout a PV residential battery storage program. However the funding for that program was supposed to come from CO2 cap/trade auctions... and that hasn't been going well.

Good news is France is starting to install more solar. Italy is continuing to add solar.
Bob Wallace
Bob Wallace
March 23, 2013
Dennis, Germany installed 7.4 GW in 2010, 7.5 GW in 2011, and 7.6 GW in 2012. If installations are slowing down it is not showing up in the data.

Now you seem to think you have data that people studying Germany's solar industry have missed. Perhaps so. However that is irrelevant to the fact that US BOS costs are too high, significantly higher than Germany's, and that Germany's FiT program seems to have cut their cost of installation quicker than the US approach.

I'll continue to hold that US installed solar prices will come down because we will find ways to cut permitting and sales cost. And we'll trim other overhead and profit per watt.

I don't see the price of panels rising above roughly 60 cents per watt and after the shakeout process is finished I think we'll see them start down once more as higher efficiency panels, more automation and higher volume manufacturing further lowers the cost to produce.
Scott McMeekin
Scott McMeekin
March 23, 2013
I can't think of any promising industry, from railways in the early 19th century to PCs to internet startups, goes through a period where a proliferation of entrants and supply leads to a crash in profitability and a shakeout. This one might be bigger, because of the role of subsidies in stimulating the growth of supply and suppliers, but the pattern is similar. There will be a shakeout and the strongest participants will survive, margins will recover to the point where they can sustain R&D and progress will continue.
Dennis Heidner
Dennis Heidner
March 23, 2013
Bob, the point on the FiT being so large that it didn't make a difference for tree shading -- was that their projects were being financed by low cost loads (3%) with little paper work, from a quasi-government branch that didn't care about the design. They financed the project based on the labeled ratings. Early on FiT was so large that even 50% daily shading would still payback. Now at below the retail rate - I suspect installations are getting smaller and more carefully placed. As a result there are signs of a slow down in the German installation business.

That means the acquisition costs for the German installs will begin to climb as they need to do more work to show payback for customers.

The overhead administration costs between Germany and USA should be within perhaps 20% of each others costs. But I believe the USA overhead portion was MANY TIMES more than the German soft BOS costs.

I would also think that the large third party installers already do enough installations do spread that administration cost over many installations and drive it down comparable to the German numbers. But I don't see that show on the studies.

John, "Thus while they may have driven down their cost of manufacturing, they have not weathered the reduction in cost per watt due to competition in a competitive market" One reason for the above action occurred is that they manufacturing and already selling them well below the cost incurred. Normally on any large manufacturing process, you start up with higher costs, then drive the costs lower with lean manufacturing, process and quality improvement, and increasing volume. That drives the cost lower while you can make a profit to re-invest in more R&D for the next generation products. But when you build at loss, you don't design for the future AND it is hard to spend money to improve how you can loose more money. It wasn't sustainable. The excess production and oversupply hurt nearly all the vendors.
John Nistler
John Nistler
March 23, 2013
Dennis H. Valid point. HP, Dell and the entire PC hurt all of the companies mentioned who stayed concentrating on large computers. But CDC specifically moved into real estate since they owned a lot of property and then basically were not able to compete with IBM, Honeywell or Amdahl. As Robert Noyce of Intel pointed out to me, they lost focus on their core business.

Sunpower has done the same. PSIDA GR LLC is now offering a PVac500 system that uses a 19% efficient, 500 watt panel with better on-panel inverter capability and simpler installation capability for rooftops and carports. We do not try to compete with our customers for power purchase agreements and work towards making it easy for our customers to obtain our systems. Since our total system cost @ $1.91 per watt (without on panel storage) includes panel, inverter, hardware and AC wiring harness while Sunpower charges more then $2.00 per watt just for their panels (by the time you go through their distributors its closer to $5 plus per watt) - I believe they have truly lost focus on their core business. Getting their cost of manufacturing down and providing easy access for their customers to their product.

Firstsolar is making the same mistake. Yingli, Trina and the others made a different mistake. That of loosing track that they are in a technology industry. They did not concentrate on improving their product offering, aka, kWh production versus watt and solar conversion efficiency. Thus while they may have driven down their cost of manufacturing, they have not weathered the reduction in cost per watt due to competition in a competitive market.
Bob Wallace
Bob Wallace
March 23, 2013
"As the choices of brands shrink -- the prices will begin to climb. "

You're assuming that the number of brands will decrease to the point at which there is a virtual monopoly.

I really doubt that. We have over 600 panel manufacturers in the world and only 150 or so are expected to fail. Even a dozen manufacturers should provide more than enough competition.

--

Yes, the German FiT worked because it made solar an investment opportunity. That is exactly my point.

(Those people who installed under a tree made poor investments and would have received no significant FiT because they would have had no Fi for which T would have been paid to them.)

The big point is, installed solar prices in the US are coming down. That means that we hit grid parity in more and more parts of the US. That means that more and more people are going to install solar. And that means higher volume which leads to lower prices.

The cost of " federal taxpayer ID, then often a state business license, sometimes a county license, then possibly a business license for each city that you do business", a bookkeeper, an attorney on retainer, an ad person, a web guru, etc. are all costs that decrease per watt when you install more watts.
Dennis Heidner
Dennis Heidner
March 23, 2013
Bob, the permits are high for all types of installations. Washington State charges a pretty penny to install a residential standby generator AND it can't be combined on a simple permit to install a new lighting circuit.

The companies selling standby generators would probably make a lot of noise if solar PV generation was given a preferential treatment. That's the point I've been trying to make. When the economy crashed - fees and schedules were shuffled to "simplify" them. And in almost all cases it was done with the approval of the city, or county, or state governments.

I've seen it for business permits also. You need the federal taxpayer ID, then often a state business license, sometimes a county license, then possibly a business license for each city that you do business. Those are not necessarily building permits, but keeping track of the licenses, and buying a license for another city that you might have a customer in... is expensive.

Perhaps its the tracking of all the business licenses that is the big chunk of the "overhead administration".

I disagree with you on the FiT. I have hundreds of pictures of solar installations in Germany that took advantage of high FiT incentives, but installations were marginal -- lots of shading by trees and cathedral spires. The FiT worked because it was combined with VERY easy and low cost financing. It became an investment opportunity!
Bob Wallace
Bob Wallace
March 23, 2013
There was an article on Greentech Media a few weeks back which reported (IIRC) that the most efficient Chinese panel manufacturers were producing for less than 50 cents per watt (their costs).

If one can produce for 50 cents and do so in large volume then selling for under 60 cents, or even less, can mean good profits. If you sell enough "whatevers" per day you can make good money even if you make only a penny per item.

I can see panel prices bouncing around their current price for a while, perhaps even a couple of years, as the lower efficiency companies are forced out and surplus capacity is absorbed. But during those times the most efficient manufacturers are going to be working to further lower their costs.

Apparently there are now new more automated processes which could be installed and which would lower costs, but demand isn't sucking up existing product fast enough to make installing that equipment profitable. And increases in panel efficiency are pretty much automatic manufacturing cost reductions.
Dennis Heidner
Dennis Heidner
March 23, 2013
John, in Europe many of the manufacturers were also the designers, distributors and installers. Sometimes with their own panels, sometimes with another companies panels. Going after the complete stack in solar PV market worked well around the world and in the US.

To be fair, CDC's competition in the early days wasn't HP, Dec, Tandem or DataGeneral. It was Cray, IBM, Amdahl, Honeywell, Univac, Bull, etc. Early HP and Dec computers were mostly laboratory machines - not aimed at the heavy duty crunching of a cyber. I believe CDC was gone before Dell became much of a market player.

The graph above that Paula provided are mostly Chinese. There are of course manufacturers from Korea, Germany, Japan, US and elsewhere.

Sunpower probably feels that their panels are unique enough to warrant the price. While we like to think of all solar panels as being simple off the shelf commodity items; in reality they are not. Sunpower with its larger size and higher voltage are good example. If a Sunpower module fails, you need to replace it with an equivalent Sunpower module (IV curves and dimensions make the modules unique.)

I think your point about the distribution chain availability is good. I have noticed a significant shrinking of choices available. As the choices of brands shrink -- the prices will begin to climb.

There are new homes going up with solar. Energy efficiency and self power production is now starting to be ranked up there, nearly as important as a bathtub in the master bath suite....
Bob Wallace
Bob Wallace
March 23, 2013
Let me suggest that few county/city building departments are enjoying significant revenue from solar permitting at this point in time. I doubt solar permits are a cash cow that they would work hard to protect.

And, at the same time, let me suggest that if some jurisdictions attempt to hold permitting fees high they will experience the wrath of unhappy citizens who will make their feelings know to elected officials.

If permitting is streamlined as is being attempted in a few places and it successful then political pressure will spread the new approach to most places. Even the most politically conservative don't like to pay the government more than they have to.

As for selling/customer acquisition costs, those should be automatically reduced to a minimum by falling system prices. When the neighbor gets a system and brags about how much money they are saving you'll get the number of the installer and order up a system for yourself. There will be no "sales", just someone filling out a purchase agreement.

Germany chose a more successful route to lower solar prices. By using a FiT they created an incentive for people to install at the lowest possible cost. That maximized profits for the system owner. Because people could actually make money by owning solar, and not simply cut their utility bill, a higher installation volume was achieved sooner. Higher volume = more companies in the business = more competition = lower prices.

I think we'll see 2013 as the year solar really takes off in the US. We've largely recovered from the recession and our cost of solar is pretty good. I expect installation rates to significantly increase and that should start to give us the really efficient installation companies who will carve away at BOS costs.
John Nistler
John Nistler
March 23, 2013
If I note the companies listed in this analysis there are some reasons that each of these companies are in trouble. Sunpower can not for example get their manufacturing costs under $1.05 per watt and their policy of not providing easy access to their solar panels hurt their sales. Second, many of these companies have actually started competing with their customers by moving into Power Purchase Agreements which is really more of a financial, real estate and operations versus base manufacturing area. Essentially the same thing Control Data of Minnesota did in the early days of computers which essentially cost them the ability to compete against HP, Compag and Dell computers.

Permitting costs for new home solar install is not extra cost for home builders in the USA, but I do not see any of these new homes going up with solar installs. Thus to point to permitting being a major issue ignores something else that is fundamental. What is it that is truly limiting solar rooftop installation in the USA?
Dennis Heidner
Dennis Heidner
March 22, 2013
...continued...

I don't mean to sound like the world is coming to the end - but I honestly do not think that we (US) will squeeze the BOS cost as much as people hope. And I think we will see adjustments to the German $/watt that show it flatter or higher than originally projected.

Now having said that, solar has/is certainly nearing parity in many markets. It will continue to do so. It would reach parity faster of many of the external costs for other energy sources are not ignored AND/OR subsidized. In fact it some case I can see that if the tax deduction/credits for fossil fuels were removed, wind/solar PTC removed that solar might still be at parity. That is good. What is not good is that to reach that point - we (consumers) expect the manufacturers to sell products at a loss. Certainly we can't expect installers not to make profits, nor can we expect one segment of a city/county/state's building/contracting industry to cover the costs for another portion.

While I do not doubt that prices will continue to drop as installers continue to become more efficient. I do not see the huge drops will continue. Price drops that potential residential customers are beginning to expect. Instead I think that if the economy is indeed turning around that we may actually see prices start to increase - as labor markets tighten up, as we experience a reduction of solar modules available (because of the market consolidation), and as we see the loss of installers in the US.

As Paula suggested - the industry needs to see profit - at MANY points in the value stream. Not just the installers.
Dennis Heidner
Dennis Heidner
March 22, 2013
Bob, cities and counties don't make money on permits, but those fees can be more than half of their operating budget. High fees are not everywhere - yet one of the items of focus on the BOS studies is the "large portion" of the slice that is allocated to permit fees. My point is that I believe the high permit fees may be more localized to states, cities and counties that are using the fees to cover a significant portion of their planning and inspection departments operating budgets. If so, they will not be willing to reduce fees for solar project. If they did, there would be other construction and trade industries protesting that their costs have now gone up. It is the squeeze budget here and it pops up higher over there... problem.

Customer acquisition cost in Germany are lower for a couple of fundamental reasons that have been glossed over. First there has been a LONG history of the German government, states and many cities promoting green in Germany. They have a political party called Green. The perils of climate change and the need for renewables have been taught in school and integrated into their education system for nearly twenty years. Renewable energies, the environment are very frequently reported items - sometimes dominating the news.

Germany long ago made financing of solar for residential items easily possible via KfW. It is recognized and essentially treated as transferable second mortgage. It transfers with the house. Solar is treated equally with home weatherization efforts. Adding solar PV/therm was an path to meet energy reduction targets for a residences when certain renovation or heating system changes were made. In short the German government promotes solar REDUCING the need for the installers/distributors/manufacturers to market.
Bob Wallace
Bob Wallace
March 22, 2013
All you have mentioned are small difficulties for those companies which will eventually come to dominate the market.

As the industry matures the issue of getting workers and materials onto roofs safely will streamlined with things like scissor scaffolding or more innovative developments. Equipment will be invented in order to drop costs and win more contracts.

Permitting fees will drop as companies lean on local supervisors to lower permitting fees. I doubt that counties/cities make money on permits and inspections, just recover their costs. In the Broward County approach the cost of a pre-inspection and plan review have been eliminated. If this works with no or few problems then pressure will be applied to other jurisdictions. It will come from both installation companies and from end-users who want to lower their system costs.

As I travel around the world I have no trouble recognizing that the US is as, or more, efficient in getting the job done than most other countries. Elsewhere I see scaffolding put up one piece at a time, concrete carried from mixer to where it is needed in wheelbarrow or head-carried basket. In the US I see self-powered scaffolding rigs and concrete pumps.

We could see a time at which the roof mounts are installed by a single roofer in an hour or less. (Insurance for a roofer is quite expensive.) And then the panels are installed and connected by a robot working from the back of the truck which hauled it and the panels to the site.

This isn't rocket science. It's a highly repetitive task that can be largely automated given adequate scale.

Every company in the US knows that if they don't constantly endeavor to keep their prices low, to keep lowering their prices then someone else will eat their lunch.
Dennis Heidner
Dennis Heidner
March 22, 2013
Bob,

Our labor costs appear to be higher, but I am pretty sure the difference is really caused by two problems that previous surveys missed.

First, the trades used on residential roofs for the installation are ROOFERS, and the connect the string dropping the wire into the house. In Germany roofers cost less than electricians.

Second, I do not believe all the site labor costs are really being captured. Roofers do not install scaffolding. That is the work of another trade. Scaffolding is almost always used on the German houses. More than 1/3 are two or three stories with tile roofs.

Prior to the late 2000's, not all states had adopted state wide building codes. There were some states where the building, electrical, fire code, etc were entirely upto the local jurisdiction. In many the smaller areas - the permit fees are already zero. In other areas -- they are quite high --- because the permit fees pay for the building, planning and inspection departments. Rapidly changing the permitting process across the US will not happen. Not unless someone throws in money to pay for the lost revenue that some of the local authorities are getting.
Bob Wallace
Bob Wallace
March 22, 2013
(Continuing - hit the word count wall.)

There is one cost savings that Germany will continue to enjoy that should keep our installation cost a few dollars per site higher.

Germany is able to do a lot of non- roof penetrating installations where we, with generally higher winds, need to secure racks to the structure. But that can't be a major expense. Locate the rafters, bolt down a few rack supports and make them water tight. That's an hour or two of labor at most. And labor is not a huge part of the BOS costs.

We, in the US, will have the advantage of a much larger overall market. That will allow for major installation companies, robust supply streams, and greater economies of scale.
Bob Wallace
Bob Wallace
March 22, 2013
Dennis, I find your speculation unconvincing. What would help your prediction that US BOS costs will remain far higher than German costs would be some examples of why US costs can't be cut.

I posted an example of how one county in Florida is trying an approach which should greatly cut the cost of permitting. There are other approaches being tried elsewhere, Vermont, I seem to recall, modified their permit process.

There's no reason why permitting should be expensive. The role of government here is to see that the installation is done in a safe manner. Require the installer to be licensed, to be insured, and to purchase a performance bond. Let the installer pull a permit on line at zero cost to the government. Have the building inspector do a final before the system is switched on just as would be done for a new dryer outlet in your garage.

Germany has lower BOS costs due to lower customer acquisition costs, lower sales costs and lower per watt profit. That speaks to me of a product that is priced too high, that takes sales effort with a large portion of potential customers walking away due to sticker shock. And of companies charging more per installation due to lower competition and overall low volume.

As prices fall solar systems will sell themselves. Installation crews will be kept busy constantly moving from site to site. Operational overhead will be spread over more installations. More installation companies will enter the field and competition will further drive down the cost.

There is no country, as far as I can tell, which is as good about scaling up an enterprise to the point where profits come from volume. Take the big box stores and major internet retailers for example.

We've been tracking Germany's price with about a two year lag for some time. Their FiT subsidy approach has been more successful than our federal tax credit approach. It's driven their installations faster.
Dennis Heidner
Dennis Heidner
March 21, 2013
First I have to ask Paula to forgive me for my late night typo where I addressed her as Paul. Tired eyes and late nights do not mix.

Bob_Wallace, I do not believe that we (US) will ever get the BOS cost as low as Germany. Not because we don't have the will power, but because I believe the German installed costs DO NOT accurately reflect all of the installation costs. With the exception of the permitting and "administrative overhead" costs I think the US numbers may be very close to the actual German numbers.

Permitting costs in the US are often a result of our insistence that the users of a government service pay for the cost of using government. We've been pushing more and more over the years for higher costs to use the national parks, e.g. make them recover the costs of operating. We get unhappy when various agencies don't recover enough money for the land leases, etc. Permit costs have been a means to "extract" from the users of the service money to pay for the service. I can see big fights in future over why a renewable industry should get a break on a permit, when a consumer that needs a hot water replacement must pay the full permit fees.

Dealing with permits - in many cases implies restructuring how government funds its services. And we've seen lately how well we've been able to reach a consensus for that....

The overhead and administrative (O&A) portion of the BOS is the item that I am really quite interested in understanding what goes into it and why. This seems to be the area that has the most opportunity for possible savings; however those savings might only appear to exist - because we don't understand the content and value of the O&A.

It is also possible that systems in Germany have O&A costs that were missed in the surveys -- or picked up by some other government entity.
Nate Blumenkrantz
Nate Blumenkrantz
March 21, 2013
Thanks Paula for speaking the truth and laying it all out there for us!

I couldn't agree more that what's happening is not sustainable. It seems to me that, in the short-term, prices would have to go up significantly to turn those net losses in figure 2 to healthy gains.

A simple way of looking at this: if the manufacturers wanted to just break even on the amount of inventory they sold in 2012 they would have to raise their prices 3-40%, or 12-40% excluding First Solar (i.e. they would need to raise their revenue by this percentage to cancel out their net loss). That means a $0.70/W price would go up to $0.78-$0.98 (excluding First Solar).

I believe the sooner this gets hashed out the better for the industry, especially since price per Watt will continue to come down in the long term. The question is how to move this along… hopefully nobody is investing more money in the weaker manufacturing companies that are doomed to fail.
Bob Wallace
Bob Wallace
March 21, 2013
Here's the sort of stuff solar needs. Not a few more pennies cheaper solar panels - cut the installation costs....

"Making energy from the sun seems a no-brainer for the Sunshine State, but cost has proven to be a hurdle. Broward County has taken a big step to cut costs for solar-panel systems on rooftops and homeowners, businesses and other counties are taking notice, a Go Solar conference showed Friday.


With help from a $673,000 federal grant, Broward has simplified the process to apply for permits for roof-top solar-panel systems, saving time and money — perhaps thousands of dollars per system.

Click on a website, choose one of several pre-approved solar-panel system designs, and you can get the go-ahead online for that installation in select areas in the county, officials said.

"It can all be done electronically in a few minutes — instead of a few weeks — in some cases,"



http://www.renewableenergyworld.com/rea/news/article/2013/03/floridas-broward-county-encourages-solar-energy-with-easier-permits
Bob Wallace
Bob Wallace
March 21, 2013
It's shakeout time. I suspect the most efficient manufacturers are producing panels for around $0.60/watt. Certainly not much higher. Possibly lower.

For a while even the most efficient will loose money as prices dip to and below production cost until many of the 'barely hanging on' companies go under.

A year or two from now the most efficient should have figured out how to sell at 60 cents and make a decent profit via volume of sales. Solar panels are becoming a commodity.

Any price in the 50 to 60 cent point is great for solar. The real savings need to come from cutting BOS costs. Do that and we can drop below Germany's current $2/watt installed price and march on toward $1/watt. It's not saving 10 cents on the panels we need. It's saving dollars per watt on installation costs.
SAM VANDERHOOF
SAM VANDERHOOF
March 21, 2013
Paula,

Great review of the PV prices and history !

I confirm your details, the information you have provided is "spot on".

Thanks also for your insite.

Sam V.
John Nistler
John Nistler
March 21, 2013
Gescher3, not sure if its unbounded optimism or 20 years experience with the semiconductor industry prior to starting PSIDA. Fact is, there will be winners and losers and the losers will always be in the news, whereas the winners never get notice until they are huge. Take Intel and AMD for example. I doubt that the discussions on microprocessors would have truly hit the headlines in the early days of Intel. Maybe the San Jose news in the Business section but never even the front page of the business section. People loose track of the fact that at one time Intel was a start up with 7 people.
ANDERSON MARK
ANDERSON MARK
March 21, 2013
An excellent article, Paula. You have reinforced the importance of examining the entire history of an issue before attempting to arrive at conclusions and policy decisions.

I managed design/construction of a multi-Mw PV project in 1982-85, then went on to other projects, mostly nuclear power plants. In 1992, I returned to PV, briefly, to start up a large utility PV program to install systems on customers' homes and businesses and then moved on to other (non-PV) projects. To date the original project (with subsequent additions) and the community-based program have installed about 10 Mw of PV capacity; all of which is currently producing power. (While it's tempting to be an opportunist and claim credit for the impressive decrease in PV cost (your Figure 3) between 1982 and 85, doing so would be subverting actual history, as there were many forces at work at that time, so I'll restrain myself).

My limited involvement in PV has led me over the years to attempt to follow the costs of both installed systems and PV panels, and to follow R&D efforts to reduce panel manufacturing costs/increase panel efficiency; as these are key elements to PV becoming competitive in the marketplace. To say that the picture in the past ten years has been confusing is a gross understatement. Your article is a great help in clarifying the situation.
Gustav Escher
Gustav Escher
March 21, 2013
This thread is proof that a great article spurs great comments !!! My prize for "answering the question" goes to dennis; the prize for "unbounded optimism" goes to John; the prize for "philosophical sidebars" is split between shanmugham and narasimharao; the prize for a "neat tangential comment" goes to anonymous and the prize for "explaining things really well" goes to hakki-surel. Thanks all !!!
ANONYMOUS
March 21, 2013
An informative article!

A question? How much of the operating loss with manufacturers in Fig 2 is to service debt? If there is M&A activity to come, this cost will disappear!

The big reward will come when the market grows to match manufacturing capacity. It is just a question of still being around when that day comes.
Dennis Heidner
Dennis Heidner
March 21, 2013
It is a good article Paul.

gescher3, I think a sustainable price per watt could easily be down around $0.50 in another five or ten years. It isn't just how low the price/watt. It is also the SPEED at which the prices were falling. Literally new panels were coming off the production line and being sold below cost... day in and day out. If the prices and been $0.25 or $0.35 more per watt the last two and a half years, I think we would have a very different story. There would be many more companies still in the hunt.

The free fall module price may have triggered a solar boom, but it will also be the cause of the more damaging solar bust. I am seeing installers get out of the market. Wurth Solar (Germany) is getting out -- and they did quite a few of the larger solar plants in Germany and Italy.
John Nistler
John Nistler
March 21, 2013
This article reads exactly like other semiconductor articles of the 1980's and 90's talking about how the price of electronic devices could not reduce any further. The industry's solution was more standard devices and greater number of transistors, or function per square area.

For solar PV it also translates as the same, better function, aka, more kWh per watt and higher solar conversion efficiency. Address these two issues and your profitability will be maintained. Fail to address either, and you will be acquired or go out of business. As a PV supplier, this is what we have done with the PVac500 watt system, a single panel AC system using 19%, 500 watt solar panel, on panel inverter, inclusive easy to install hardware and AC quick connect parallel wiring with optional on panel storage. @ $1.91 without storage, it allows residential installs to be at the same price comparison as utility installations.
Hakki Surel
Hakki Surel
March 21, 2013
gescher3,
estimating mature market pv prices, in a location where kWh/kWp ratio is around 1800 per year pv+BOS of $1600/kWp will be amortized in 10 years with electricity prices of 8-9cents. kWh/kW 1800 locations are not so abundant in people crowded area especially in Europe. Therefore upper limit for the pv prices should be around $ 0.8 per Wp. With this panel price manufacturing industry should be satisfyed to make further R&D. I believe it is doable.
Best Regards
NARASIMHARAO T V L
NARASIMHARAO T V L
March 21, 2013
We should stop brooding on past data on ASP, CAGR, Demand etc. It is over and on us. Now the market analysis should be seperated for consumer durable PV ( for use in small or domestic systems)and professional PV (for off-grid or grid tied). Price competetion, lower prices at the compromise in quality and module warranties in consumer PV is justifed. This segment will mature seperately. While professional PV market should be cultivated with back-up gaurantee/warrantee on BOS. Then the market comparison study will be more relevant.
shanmugham kangala
shanmugham kangala
March 21, 2013
Cost of Solar PV power is now competitive compared with Wind Power. Hybrid systems - on small scale for providing power to UPS and serving as auxiliary supply system, may now be technically and commercially viable. Such a step will be mutually helpful and beneficial to the industry. Help from policy makers and Utilities by extending support and making it more attractive to existing Wind power producers will make it more attractive. Initiatives are requested from Manufacturers, RE power producers and Investors. Posted by knsh06@gmail.com
Gustav Escher
Gustav Escher
March 20, 2013
IMHO, a great article. Thanks, Paula Mints. Having said all you said, what do you think will be the economically sustainable price for PV panels in a "mature" market? $1.00?

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Paula Mints

Paula Mints

All Solar, All of the time -- I started my solar market research career with Strategies Unlimited in 1998, moved to Navigant in 2005 and am now I am excited to announce the founding of a new company, Paula Mints Solar PV Market Research....
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