RCT Solutions GmbH – Solar Manufacturing Engineering
End-to-end engineering for giga-scale PV manufacturing, from polisilicon to module.
Dhirubhai Ambani Green Energy Giga Complex
India’s 20 GW vertically-integrated solar campus in Jamnagar, Gujarat
Client: Reliance New Energy (Reliance Industries Ltd.)
Location: Jamnagar, Gujarat – India
Site: 5 000-acre “Green Energy Giga Complex” inside Reliance’s SEZ
Phase-1 Target: 10 GW modules by 2026; scaling to 20 GW fully integrated output by 2030
Value Chain: Polysilicon → Ingot → Wafer → Cell → Module (plus glass & POE)
CapEx: ≈ US $10 billion complex investment
Milestones: Ground-break 2022 • First GW-scale module line 2024 • Ingot-wafer hall commissioning 2025
Reliance’s Jamnagar refinery campus—the cradle of India’s oil boom—is being re-imagined as a fully electric Green Energy Giga Complex. Five giga-factories are rising side-by-side for PV panels, batteries, green hydrogen, power electronics and fuel cells. The solar wing is the anchor: a 20 GW ingot-to-module line designed to end India’s dependence on imported wafers and cells while feeding the government’s 500 GW-by-2030 renewables target. The first GW-scale module line went live in 2024; upstream ingot and wafer halls follow in 2025, making Reliance the country’s only player with a truly end-to-end silicon chain.
- Installation & Commissioning (Ingot + Wafer Zone) - 1. Rigging, precision levelling and hook-up of crystal-growth furnaces, wire saws, slurry systems and metrology tools
2. Cold/HOT runs, FAT/SAT execution and performance sign-off to Reliance QA standards - On-Site Engineering & Operator Teams - 1. Resident RCT engineers managed contractors, issued daily QC punch-lists and HSE briefings
2. Cross-trained Reliance operators during live commissioning to ensure seamless shift handover - Operational Documentation Suite - Delivered a fully ISO-compliant library of equipment handbooks, standard operating procedures, emergency-response guides, and master specification/BOM dossiers—bilingual (EN/HI) and integrated into the plant’s digital knowledge base for instant shop-floor access.
- Workforce Enablement - Commissioning doubled as a Solar Academy: classroom theory, hands-on practice, and live KPI dashboards ensured Reliance crews could run the ingot- and wafer lines at full speed from Day 1.
2 GW ingot- & wafer line commissioning: Q2 2025
98 % first-pass FAT/SAT acceptance on upstream toolset
< 40 days from first crystal pull to name-plate wafer yield
200 + local engineers & operators trained during start-up
40 % reduction in wafer lead-time vs. previous import model
Precision Hook-Up
RCT engineers aligned more than 200 crystal furnaces and 320 high-speed wire saws to micron-level tolerances—laying the bedrock for Reliance’s 20 GW ambition.
Living Playbook
All SOPs, handbooks and emergency manuals were delivered as an interactive, bilingual library accessible via tablet on the factory floor—giving operators instant answers, shift after shift.
Rapid-Ramp Training
Commissioning doubled as a Solar Academy: every tool hand-over included classroom theory, hands-on practice and live KPI dashboards, ensuring Reliance crews could run at full speed from Day 1.
