Recently, Christian Comes, Director of Business Development Europe at Huasun Energy, was invited to appear on Masters of Manufacturing, a flagship program by the renowned industry media platform ENF Trade TV. In this episode, he offered a comprehensive insight into Huasun’s integrated HJT industry chain, as well as the company’s intelligent manufacturing capabilities.
As the first company worldwide to establish a fully integrated HJT value chain, spanning from silicon ingot and wafer to HJT cell and module—Huasun has built an annual HJT production capacity of 20 GW, with cumulative shipments exceeding 13 GW to more than 80 countries and regions. Through continuous innovation and lean manufacturing, the company is accelerating the large-scale adoption of high-efficiency HJT technology and reinforcing the global competitiveness of Chinese PV manufacturing in high-end industrial applications.
Technical Depth: Systematic Innovation from Materials to Design
At the cell level, Huasun’s self-developed heterojunction cells achieve a stable mass-production efficiency above 26%, forming the foundation for high module power output. The application of Zero-Busbar (0BB) technology expands the light-receiving area, enhances bifacial generation, and reduces silver paste consumption—striking an effective balance between efficiency and cost.
In terms of module assembly, Huasun adopts a dual-glass design, with front and rear glass undergoing different heat-strengthening processes to enhance mechanical strength and durability. For specific scenarios such as vertical installations, Huasun also offers a 2.5 mm reinforced glass option for enhanced robustness.
The Himalaya Series modules feature an anodized aluminum alloy frame that provides excellent corrosion resistance and optimized mechanical load capacity, while further enhancing bifacial power generation through refined structural design.
Christian explained in the program that encapsulation materials were initially designed to serve two key functions: bonding the layers together and preventing moisture or impurities from entering the module. However, Huasun has advanced this concept with its Light Conversion Film (LCF), which converts UV light into blue light and significantly improves the UV resistance and long-term durability of HJT modules. Combined with PIB (polyisobutylene) edge sealing, which offers up to 100 times better water resistance than conventional silicone, this structure provides exceptional reliability and long-term protection in challenging outdoor environments.
Manufacturing Excellence: Vertical Integration for Performance and Quality
As the world’s first manufacturer to achieve full HJT industrial integration, Huasun leverages self-developed and customized production systems to enhance both efficiency and quality, building a distinct and hard-to-replicate industrial advantage.
Starting with wafer manufacturing, Huasun applies FBR (Fluidized Bed Reactor) and CCZ (Czochralski Continuous Casting) technologies to produce ultra-thin wafers optimized for HJT processing—reducing material consumption while improving conversion performance.
In cell production, Christian highlighted three key steps: amorphous/microcrystalline silicon deposition, transparent conductive oxide (TCO), and screen printing. For 0BB cells, Huasun adopts a simpler two-step screen print (SP) process to deliver superior product quality and enhanced electrical and cell-to-module (CTM) performance while lowering paste usage and energy consumption.
The module assembly process is highly automated and precisely controlled—from string alignment and uniform PIB sealing to lamination and curing with tight temperature management. Each stage operates under standardized procedures and real-time monitoring, ensuring consistent output and mechanical reliability across every production line.
Quality Assurance: Data-Driven Quality Control Throughout the Process
Reliability is the foundation of efficiency. To guarantee stable performance, Huasun has established a closed-loop, data-driven quality control system that covers every step of production.
EL (Electroluminescence) testing is performed after both stringing and lamination to detect microcracks, while power testing is continuously calibrated using third-party certified reference modules to ensure measurement precision.
By applying machine learning algorithms, the system can automatically analyze EL images and detect appearance defects with high precision, significantly improving inspection speed and consistency. All inspection data are archived for full traceability, ensuring each module meets the company’s stringent reliability standards.
Comprehensive Assurance: From Manufacturing to Global Delivery
Huasun’s pursuit of excellence extends beyond production to logistics, packaging, and customer service—delivering value throughout the entire lifecycle.
Packaging solutions are tailored for different product types. For example, frameless vertical modules utilize a customized anti-impact design that minimizes breakage during transport. Shock sensors are installed inside containers to monitor vibration and handling conditions in real time.
In key regions such as Europe, Huasun has built localized teams and multilingual service networks, offering fast, on-site technical support together with trusted local partners. This ensures quick resolution of customer issues and consistent service quality from factory to field.
Through the Masters of Manufacturing feature, Huasun Energy showcased to the global PV community the maturity, scalability, and reliability of its integrated HJT industry chain. As heterojunction technology continues to evolve and gain market adoption, Huasun remains committed to driving efficiency, reliability, and sustainability through innovation and full value-chain integration—driving the solar industry toward greater efficiency and reliability while empowering the global energy transition with next-generation solar manufacturing.
