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Don't Miss The Great Solar Debate: Where Does the Global Solar Industry Stand? Click Here to Register! ×

Suntech: Factory Closure and a Train Wreck in the Making

Ucilia Wang, Contributing Editor
March 12, 2013  |  4 Comments

Suntech Power, feeling the sting of the tariff the U.S. government imposed on silicon solar cells from China, said Tuesday it will shutter its Arizona factory on April 3 and let go of 43 employees.

High production costs, along with the tariffs and an imbalance of supply and demand in the global solar market, are to blame, the company said.                                                  

The company opened a panel assembly plant in Arizona in 2010 during a time of optimism about bringing solar manufacturing back to the country and the emergence of the United States as the next big market.   

The decision is not surprising considering that the company has been dealing with internal drama and external market forces that have caused dozens of solar companies around the world to declare bankruptcy over the past two years. Still, the factory closure symbolizes a dashed hope for luring investments from abroad to complement domestic efforts to build a booming solar manufacturing industry.

The Chinese company only opened the factory in October 2010 that had a production capacity to produce 30 megawatts of solar panels per year. Its original plan was to expand to 120 megawatts at some point. Suntech did scale up to 45 megawatts before cutting it back to 15 megawatts. Last November, it announced it would cut two of the three production shifts and cut the workforce there by about 50.

Suntech is one of the largest solar cell and panel makers in the world, and it has risen to the top by building large factories in China to gain scale and reduce costs. Along with other Chinese manufacturers, Suntech has benefited from strong support from the Chinese government and state-run banks. The U.S. doesn't offer nearly the same type of backing. But through the 2009 stimulus package, the U.S. government was doling out billions in grants, loans and tax benefits to help finance solar technology manufacturing and installation in order to create jobs. Many state governments offered their own incentive packages to attract solar manufacturers looking for new factory sites.

Product costs were higher, naturally, at the Arizona factory from the start. The difference was 10-15 cents per watt between the factory and Suntech's manufacturing home base in Wuxi, China, a company executive said in December 2010. The company was identifying ways to narrow that gap.

Starting in early 2011, however, signs that the global solar market was facing a glut of solar panels began to show. First Solar, an industry bellwether, reported flat sales and lower earnings for the first quarter of 2011. Other manufacturers followed with poor earnings or escalating losses. Long-time solar companies such as Q-Cells in Germany filed for bankruptcy. The U.S. government's efforts to promote solar manufacturing produced a high-profile failure in Solyndra­, which was trying to scale up its manufacturing at a time when solar panel prices were falling quickly. Companies with ambitious plans to enter or expand its reach in the solar market, such as GE, shelved their plans.

Competition intensified and grumblings about the political and financial support the Chinese companies were receiving from their government grew louder and led to trade complaints filed in the United States and later Europe. Last year, the U.S. government imposed tariffs on silicon solar cells made in China after a yearlong investigation. Suntech faces a 35.97 percent tariff for bringing solar cells from China and assembling them into panels in Arizona. Suntech could use cells made elsewhere to circumvent the tariff, but Suntech has maintained that the tariff makes it difficult for it to compete because it wants to use the more technologically advanced cells from its factories in China.

But the tariff is only part of its troubles that have caused the company to crumble like a train wreck. Last year, its own investigation revealed that a fund it controlled to finance solar power generation projects in Europe, called Global Solar Fund, used faked German bonds to guarantee some of its project funding. Around the same time, the fund and its management came under legal scrutiny in Italy when a criminal investigation found evidence that the fund was building projects illegally to take advantage of a government subsidy for producing solar electricity.

Suntech last week announced a settlement with Global Solar Fund.

Suntech faced the delisting of its shares on the New York Stock Exchange last year when the price fell below the required minimum of $1 per share. It later regained compliance when the price rose above $1. The company has a $541 million debt payment due on March 15, but it recently managed to get most of its note holders to agree to give the company more time.

Last year, the company brought in a new CEO to replace its founder, Zhengrong Shi, who recently lost his post as chairman.

The company announced preliminary financial results last December that showed declining shipment and revenues for the third quarter of 2012. It has yet to post its earnings for that quarter. 

4 Comments

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Dennis Heidner
Dennis Heidner
March 13, 2013
Anonymous,

Any new business, or product is risky. Not just with solar, look at the entertainment industry - some movies make money - others lose money. Some oil wells are dry, some hit oil and are very profitable...

When company (solar industry)launches it is based on a business plan that tries to project price and demand for their potential product several years into the future. If the idea is novel (Solyndra) the development risks are higher and market adoption may be slower. But if they (solar manufacturer) has sufficient capital and their original business case for the demand is correct - they will prosper.

Now toss into the mix the addition of a NEW set of producers, that are using solar cells based on technology developed by others, produced at a loss with the backing of your city, state or government -- all in an effort to obtain a significant market share. Ramp up production capacity such that your plants can produce not just what the WHOLE worlds needs in one year -- but enough cells to supply TWO years worth of demand. And keep those plants running.

The results? Competing companies, Q-Cell, Abound, Solyndra, Evergreen, BP, Shell, United Solar, Schott, Schuuco, REC, Siemens, Sunways, MiaSole, etc, were forced to re-examine their business plans and either leave the market or shutdown.

The result is perhaps twenty or thirty solar manufacturers that produced a wide variety of products - some with unique capabilities are no longer in the market. New ideas, techniques and capabilities that were being developed are no more.

Those twenty or thirty major companies also used manufacturing equipment made in the US and Europe that was specialized for solar manufacturing - they have also been impacted by the loss of their customers.

So when the SunTech train wreck happens - and everyone has a chance to catch their breath - it will also be apparent that the train wreck took out a large area of the "community" with it.
Morrill Beckman
Morrill Beckman
March 13, 2013
Hmmmm...China and corruption? Who'd-a-thunk?
ANONYMOUS
March 13, 2013
I have a couple of questions about solar energy industry.

What is the major concern of solar panel manufacturers in regards to staying competitive against Chinese manufacturers?

What was the main reason why Solyndra and Abound Solar, Inc. filed for bankruptcy?
Dennis Heidner
Dennis Heidner
March 12, 2013
Hmmm..."Suntech faces a 35.97 percent tariff for bringing solar cells from China and assembling them into panels in Arizona. Suntech could use cells made elsewhere to circumvent the tariff, but Suntech has maintained that the tariff makes it difficult for it to compete because it wants to use the more technologically advanced cells from its factories in China."

What it really sounds like, it that even though raw materials are available in the US, the power is reasonably low cost in the US, the equipment (silicon processing) needed to fabricate cells is available in the US... the capital to invest in a plant within the US is not available to SunTech. That is China, wants the plants built in China and not in other countries...

Perhaps we in the US should be thinking the same?

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Ucilia Wang

Ucilia Wang

Ucilia Wang is a California-based freelance journalist who writes about renewable energy. She previously was the associate editor at Greentech Media and a staff writer covering the semiconductor industry at Red Herring. In addition to Renewable...
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