Renewable Energy, Solar & Wind Manufacturing worked example

Solar Encapsulation Cost at 99% first-pass lamination yield: a worked example

This scenario runs the solar encapsulation cost calculation on the strong side: 99% first-pass lamination yield, with every other input held at its documented default. A process engineer uses it to cost the EVA or POE lamination step when comparing encapsulant suppliers.

The inputs for this scenario

  • Modules Laminated: 8,000 modules (unchanged)
  • Encapsulant Cost per Module: 3.4 $/module (unchanged)
  • First-Pass Lamination Yield: 99 % (raised for this scenario; the documented default is 97)
  • Laminator Setup and Vacuum Cost: 2,200 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total = modules laminated x encapsulant cost/module x first-pass yield% + setup and vacuum cost) to the inputs above produces each figure below.
  • At this operating point the engine returns 29,128 $ for total solar encapsulation cost, the number this scenario is built around.
  • At this operating point the engine returns 3.64 $ / piece for solar encapsulation cost per unit.
  • At this operating point the engine returns 26,928 $ for variable solar encapsulation cost.
  • At this operating point the engine returns 2,200 $ for fixed solar encapsulation cost adder.

How this compares with the baseline

  • Against the tool's baseline example, where first-pass lamination yield sits at 97% and the headline result is 28,584 $, this scenario comes in 1.9% above the baseline at 29,128 $.
  • Use it when costing the lamination stage, evaluating an encapsulant quote, or building a module cost roll-up. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total solar encapsulation cost: 29,128 $ (headline result)
  • Solar encapsulation cost per unit: 3.64 $ / piece
  • Variable solar encapsulation cost: 26,928 $
  • Fixed solar encapsulation cost adder: 2,200 $

Run it with your numbers

  • Every input above is editable in the live Solar Encapsulation Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.