IN SUMMARY
Solar PV is one of the clearest wins in decarbonisation, producing on average 20 times fewer emissions than coal power and generating 20 to 30 times more energy over its life than goes into making it. But manufacturing solar modules is energy- and material-intensive, and that embodied footprint is coming under regulatory scrutiny. Minviro assessed the product carbon footprint of a monocrystalline silicon module, from silica extraction to finished panel, to show which stages matter most and how much supply chain choices change the result.
The footprint is large and variable. A standard mono-Si module carries between 145 and 420 kg CO₂e per m², and the total varies by around 60% between the highest and lowest-impact supply chain scenarios studied.
Silicon is the hotspot. Solar-grade silicon and monocrystalline crystal production contribute most of the carbon footprint, driven by the energy needed to purify silicon to 99.9999999%.
Electricity decides the outcome. Because coal generates more than 60% of the electricity used in PV manufacturing today, the grid mix used across the five production stages is the single biggest lever on the final footprint.
Why solar's manufacturing footprint matters
Solar PV is set to triple in capacity between 2022 and 2027, overtaking hydropower, gas and eventually coal in the global generation mix. Its in-use case is unambiguous: a module’s lifetime carbon footprint is around 20 times lower than coal power, and it generates far more renewable energy than the fossil energy used to make it. But that does not make manufacturing burden-free. The energy, metals and chemicals used to build a panel carry embodied carbon that cannot be ignored as the industry scales, especially as regulators move toward maximum carbon footprint limits, ecodesign criteria and digital product passports. Crystalline silicon dominates the market, with mono-Si accounting for over 80% of annual solar generation, which is why this study focused there.
How the study was built
Minviro ran a cradle-to-gate LCA with a functional unit of one square metre of mono-Si module, specified with 170 µm wafers and 19.5% conversion efficiency, ending at the factory gate. Background data combined Ecoinvent 3.9.1 with Minviro’s proprietary raw material data points, particularly for high-purity silicon, using the Environmental Footprint 3.1 method and focused on climate change potential. The base model uses global average production, then refines to regional examples. To test variability, the team modelled metallurgical-grade silicon from five geographic sources and three regional electricity grid mixes across the five manufacturing stages: solar-grade silicon, monocrystalline crystal, wafer, cell and module.





