Solar panels are increasingly being installed on commercial roofs, logistics centres and industrial buildings. But what happens to these panels at the end of their lifespan? The solar panel recycling process is a topic that is attracting increasing attention, particularly now that the first generation of large-scale installations is approaching the 25-year mark. For project developers and installers who consciously opt for sustainable energy solutions, understanding this process is not a minor issue, but a strategic consideration.
The way in which solar panels are manufactured largely determines how straightforward or complex it is to recycle them. Traditional glass modules and newer thermoplastic alternatives follow fundamentally different pathways, with significant implications for the circular economy and a project’s long-term environmental performance.
The crux of the problem lies in the construction of conventional solar panels. A standard glass module consists of several layers that are firmly bonded together: toughened glass, an EVA (ethylene vinyl acetate) film, silicon cells, a second film and an aluminium frame. These materials are deliberately bonded together inseparably during production to withstand wind, rain and temperature fluctuations over decades.
That durability is an advantage during use, but a disadvantage when solar panel waste management. In order to recover valuable materials such as silver, silicon and copper, the layers must be separated mechanically or thermally. This process is energy-intensive, costly and does not always yield material of sufficient quality for reuse. Furthermore, some older panels contain substances that require extra caution during processing. As a result, a large proportion of the material from end-of-life panels still ends up in landfill.
The standard recycling process for conventional solar panels involves a number of fixed steps, with each stage aimed at recovering as much usable material as possible.
In the first stage, the aluminium frames and junction boxes are removed. This part of the process is relatively straightforward and yields aluminium that is easily recyclable. The panels are then cut down to size or broken up to enable further processing.
The laminate layers are then exposed to high temperatures or chemical solutions to remove the EVA film. This is the most challenging step: the temperatures must be high enough to break down the adhesive, but low enough not to damage the silicon cells. After this step, the cells can be cleaned and, if necessary, reused, although their quality is often reduced.
In the final stage, glass, silicon, metals and polymer films are separated from one another using mechanical processes such as grinding, sieving and flotation. The recovered glass can be used as a secondary raw material, but its quality is rarely high enough for reuse in new solar panels. The overall recovery rate of valuable materials remains limited in conventional panels, which underlines the importance of a better approach.
Thermoplastic solar panels take a fundamentally different approach to the use of materials and joining techniques, which has a direct impact on how easily they can be processed at the end of their service life.
Unlike the thermosetting adhesives used in conventional modules, thermoplastic polymers can be reheated and reshaped without losing their material properties. This means that the layers of a thermoplastic panel can be separated from one another relatively easily through targeted heating, without the need for harsh chemicals or extreme processes. The material retains its quality and can be used as a raw material for new products or even new panels.
The thermoplastic solar panels Solarge’s panels are manufactured without glass, aluminium or PFAS. This significantly simplifies the material flow: there are fewer different types of material involved, the separation process is less technically complex, and the recovered raw materials are of a higher quality. The result is a panel that is not only more sustainable during use, but also retains its value at the end of its life. The panels are therefore 100% recyclable, making them truly circular solar panels in the most literal sense.
Knowing that a panel is recyclable is one thing. Being able to demonstrate what materials it contains and where they end up is a step further, and one that is becoming increasingly important in ESG reporting and tender requirements.
Every Solarge panel comes with its own C_passport®, a digital materials passport that provides full traceability of the raw materials used. This system records which materials have been processed, in what quantities and from where they originate. At the end of the panel’s life cycle, it is immediately clear which materials are released and how they can be utilised in the next production cycle.
This offers a tangible benefit to property developers and property managers who are required to meet transparency requirements relating to sustainability. The C_passport® makes it possible to substantiate the circular performance of a system with factual data, rather than merely stating intentions. This is in line with the growing demand for verifiable sustainability reporting within the commercial property sector.
In the case of large-scale installations at commercial premises, distribution centres or logistics hubs, every aspect of the life cycle is important, from installation speed to end-of-life processing. A circular design has practical implications in all these areas.
Panels that are lighter and do not contain fragile glass are not only safer and quicker to install, but also easier to dismantle at the end of the project period. This reduces disposal costs and minimises the risk of material loss. Furthermore, a demonstrably low carbon footprint, combined with full recyclability, contributes to the sustainability objectives of the building owner or tenant.
For organisations that work with sustainable solar panels As part of a broader ESG strategy, the decision to opt for a circular design is not merely a cosmetic one. It helps determine how a project will fare under future reporting frameworks and what residual value the installation will have at the end of its useful life. Solarge supplies its recyclable solar panels directly to commercial end-users, providing tailored insights based on location, roof orientation and specific project conditions.
The transition to fully circular solar energy is not a distant prospect. With the right choice of materials and traceability systems, it is already possible today to build installations that, at the end of their lifespan, do not lose their value but are returned to the supply chain.
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