Plastic-Based, PFAS-Free Solar Panels a Positive Step Towards Further Sustainability in the Renewable Energy Industry

As scientific discoveries reveal that the climate crisis is worse than expected, shifting to renewable energy generation is becoming more urgent. Over the past decade or so, advances in technology, as well as investment and market competition have driven down the cost of manufacturing solar panels making solar photovoltaic (PV) one of the cheapest sources of electricity. Between 2010 and 2020, the prices of solar modules fell by over 80% and the global weighted-average levelized cost of electricity (LCOE) for utility-scale solar PV projects fell by 85%, according to the International Renewable Energy Agency (IRENA). 

Traditionally, solar panels are made of glass, protecting the solar cell inside, which is made of silicon dioxide, which generates electricity when exposed to sunlight. However, the glass that is used in solar panels often contains antimony, a toxic heavy metal. Once the life cycle of a solar energy installation is over, the panels are often dismantled and crushed, causing the antimony and other harmful substances contained within the glass to leak into the environment. While it is indeed urgent to switch to renewable energy such as solar, it’s also important to address the environmental impact of spent solar panels, to prevent pollution and negative health effects.  

Aside from environmental issues, glass solar panels are also quite heavy, which makes them less suited for some applications, such as building-integrated photovoltaics (BIPV), where solar panels are incorporated into a structure, replacing components such as roof panels, external cladding, and skylights. With many buildings struggling with weight issues, a lighter solar panel material was needed. This led to the development of plastic-based solar panels, which are lighter and more flexible than glass solar panels. This allows plastic panels to be installed on more buildings and in greater numbers, leading to more solar energy generated and less reliance on fossil fuel energy.  

One of the pioneers in plastic-based solar panels is Solarge, a Netherlands-based developer and manufacturer of lightweight solar panels with a greatly reduced CO2 footprint. Solarge’s SOLO composite panel is composed of 63% polymers and 24% glass fibers, with the remainder composed of silicon, copper, and aluminum. Each layer, such as the honeycomb panel, encapsulant, cells, and front sheet, is carefully designed to facilitate recycling and support Solarge’s sustainability goals, making it a circularly designed product. It is also a lighter alternative, weighing only 5.5 kg per square meter versus 11 kg per square meter for conventional solar panels. Furthermore, plastic and composite solar panels are less prone to shattering due to a hailstorm, which could release glass and toxic chemicals into the environment, especially for floating solar farms. 

Solarge’s SOLO panels do not contain per- and polyfluoroalkyl substances (PFAS), also known as ‘forever chemicals’ because they do not break down via natural processes. PFAS are found in many plastic-based products, such as non-stick pan coatings, cosmetics, and textiles. In solar panels, PFAS is used to prevent degradation by improving the resistance of the panels to water and UV light. Solarge’s PFAS-free solar panels are manufactured in cooperation with SABIC, a global leader in the plastics industry.  

With the elimination of most toxic chemicals, such as antimony and PFAS, this new generation of solar panels is more sustainable, due to being fully recyclable. As more buyers become aware of the negative impacts of traditional solar panel manufacturing and the EU and US governments enforce environmental regulations and sanctions against forced labor, more people and companies will be turning towards composite solar panel manufacturers that are using more environmentally friendly and socially responsible solutions. There is still a long way to go in addressing the climate crisis. Continuous innovation in solar and other renewable energies is a must to achieve a low-carbon future and preserve the environment for future generations.