RCT Solutions GmbH – Solar Manufacturing Engineering
End-to-end engineering for giga-scale PV manufacturing, from polisilicon to module.
Adani Group
India’s trail-blazing gigafab moving from ingot to finished module
Client: Adani Solar (Adani Enterprises Ltd)
Location: Mundra, Gujarat – India
Scope: Vertically-integrated ingot → wafer → cell → module campus inside Adani’s 800-acre Electronics Manufacturing Cluster
Installed Capacity (2025): 4 GW cells & modules • 2 GW ingots & wafers – roadmap to 10 GW by mid-2026
Investment: ≈ INR 300 billion (USD 3.6 billion) in phased expansion of the Mundra Renewable Manufacturing Zone
Milestones: Ingot/wafer line commissioned Apr 2024 · Cell/Module upgrade to M10 TOPCon under way
Adani Solar’s Mundra complex began as a strategic push to localize India’s entire crystalline-silicon supply chain—reducing reliance on imported wafers and cells while meeting the government’s Production-Linked Incentive (PLI) targets.
2017–2018 • Vision & Skill-Building
Adani mapped out a vertically-integrated ingot-to-module campus inside its Mundra Special Economic Zone and sent senior engineers abroad for intensive classroom training in crystal growth, wafer slicing, and advanced cell processing.2020 • Feasibility & PLI Alignment
Detailed CAPEX/OPEX studies confirmed that large-scale domestic manufacturing could compete with imports and qualify for PLI incentives, clearing the way for vendor short-listing and equipment tenders.2022 • Design Freeze & Vendor Awards
Final 3-D factory layouts, utility designs, and clean-room zoning were completed. Global suppliers of crystal furnaces, wire saws, slurry systems, and TOPCon cell lines received purchase orders.April 2024 • Ingot–Wafer Hall Commissioned
India’s first two-gigawatt ingot and wafer line went live, giving Adani upstream self-sufficiency and marking a national milestone in PV manufacturing.October 2024 • 10 GW Roadmap Announced
At Renewable Energy India Expo, Adani unveiled plans to scale cell and module capacity to 10 GW by mid-2026 and to migrate new lines to TOPCon technology.2025 • TOPCon Pilot & Workforce Expansion
Pilot TOPCon cell lines surpassed 23 % efficiency while more than 200 engineers completed specialised in-house training programmes to support rapid capacity growth.
Adani’s Mundra hub now stands as the linchpin of India’s PV-manufacturing ambitions—an integrated campus poised to deliver 10 GW of high-efficiency solar products by 2026.
2 GW ingot-and-wafer capacity installed by on-site RCT Solutions Services teams and commissioned (Apr 2024) — India’s first upstream line at this scale.
- Comprehensive Operational Library: 10 equipment handbooks, a master specification + BOM dossier, 32 SOPs, 9 emergency-case manuals, and full on-site training materials—definitive guides for safe, efficient operation of every ingot- and wafer-production tool.
98 % first-pass FAT/SAT acceptance on the complete upstream toolset.
< 40 days from first wafer to stable, nameplate yield.
23 % average efficiency achieved in TOPCon pilot cells, beating the 22 % target.
200 + engineers and technicians certified through ongoing on-site training.
40 % cut in wafer-supply lead-time versus the previous import model.
Complete Installation
RCT Solutions’ on-site engineering and operator teams installed, aligned, and commissioned every ingot-casting furnace, wire saw, slurry system, and utility at Adani Solar’s Mundra hub, taking the entire upstream line from delivery to stable production.
Workforce Mastery
RCT Solutions authored the factory’s complete knowledge base for ingot and wafer manufacturing – 10 detailed equipment handbooks, a master specification/BOM dossier, 32 step-by-step SOPs, and 9 emergency-response manuals—then translated it into action with on-site training modules covering crystal growth, wire-saw slicing, preventive maintenance, and HSE.
The result: Adani’s engineers walked away fully certified and backed by documentation that keeps every ingot-and-wafer tool running safely and at peak yield.
