Renewable Energy, Solar & Wind Manufacturing worked example

Solar Encapsulation Cost at 70% first-pass lamination yield: a worked example

This worked example runs the solar encapsulation cost numbers for a tougher week than the baseline: 70% first-pass lamination yield instead of the typical 97%. Estimates the encapsulation cost of solar modules from film material, lamination yield and laminator setup.

The inputs for this scenario

  • Modules Laminated: 8,000 modules (held at the documented default)
  • Encapsulant Cost per Module: 3.4 $/module (held at the documented default)
  • First-Pass Lamination Yield: 70 % (the input this scenario stresses; the baseline uses 97)
  • Laminator Setup and Vacuum Cost: 2,200 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total = modules laminated x encapsulant cost/module x first-pass yield% + setup and vacuum cost.
  • Total solar encapsulation cost works out to 21,240 $ at these inputs, and this is the headline figure for the scenario.
  • Solar encapsulation cost per unit works out to 2.66 $ / piece at these inputs.
  • Variable solar encapsulation cost works out to 19,040 $ at these inputs.
  • Fixed solar encapsulation cost adder works out to 2,200 $ at these inputs.

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 25.69% below the baseline at 21,240 $.
  • Use it when costing the lamination stage, evaluating an encapsulant quote, or building a module cost roll-up. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total solar encapsulation cost: 21,240 $ (headline result)
  • Solar encapsulation cost per unit: 2.66 $ / piece
  • Variable solar encapsulation cost: 19,040 $
  • Fixed solar encapsulation cost adder: 2,200 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Solar Encapsulation Cost calculator, set first-pass lamination yield to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.