Rollable Solar — Strip-first energy plan
Print power on a moving web, roll up, ship densely, and stick nicely. Freeform layout; busbars routed later. No frame, no holes in the roof, less drama — just fast sun.
Think of rollable solar energy as power you install as a strip: you print on a moving web, ship in rolls, unroll on site, press, seal edges, and route tidy busbars later. In this post, we convert line speed and roll geometry into MW, containers, days, and carbon equivalent for quick planning.
Briefly (for the curious)
- What: thin, flexible solar laminates, printed roll-to-roll and transported in rolls.
- How fast: one 1 m line @30 m/min prints ~7.78 MWp/d. 5 m laying trailer unrolls ~38.9 MWp/d.
- Why 5 m: least seams + logistics allowed by roads with "mega-trailers."
- Sunny day exchanges: one 5 m trailer day ≈ ~133 short tons of unburned carbon (with 6 hours of sun).
- Logistics: 1 m rolls — containers; or sew near the port, roll onto trucks, and unroll the same day.
Why rolling is better than frames and glass
- Continuous, not in batches. As the stretch moves, wadding appears.
- "Fabric" logistics. Power in rolls; limited by weight, not volume.
- Glue, don't drill. PSA + edge sealing → quiet roofs and low wind load.
- Cables — later. First the tape, then tidy mains.
- Less metal, fewer steps. No frames, no holders — fewer parts for disputes.
We adhere to standards, ratings, and work with electricians. We're playful — but not reckless.
How it's made (granule → electricity)
- Entry stretch. Unrolling polymer or thin metal tape.
- Coating and deposition. Barrier → conductors → photoactive layers.
- Laser engraving. P1/P2/P3 lines form long, thin sequential elements.
- Encapsulation and lamination. Weather-resistant sealants, junction lamellae.
- Winding. Finished laminate is wound like a tape. Be fast enough to wind.
Area mass ~2–3.1 kg/m²; smooth black/white architectural finish.
Reference: 1 m rolls, containers and energy
Assumptions: width 1.0 m, thickness 2.0 mm, outer Ø 1.0 m, core Ø 0.20 m, density 180 W/m², area mass 2.0 kg/m².
Annual energy per container
| Capacity factor (CF) | Annual energy | Carbon equivalent |
|---|---|---|
| 20% | ≈ 4.28 GWh | ≈ 2,440 short tons |
| 25% | ≈ 5.35 GWh | ≈ 3,050 short tons |
| 30% | ≈ 6.42 GWh | ≈ 3,660 short tons |
Carbon factor ~1.14 lb/kWh; 2,000 lb = 1 short ton (US).
Printing performance (be fast enough to roll)
For a 1 m line at speed v (m/min): area/hour = v × 60 m²; nominal power/hour = 10.8 × v kWp.
| Line speed | kWp / hour | MWp / d. | Containers / day* |
|---|---|---|---|
| 10 m/min | 108 | 2,592 | ≈ 1.06 |
| 30 m/min | 324 | 7,776 | ≈ 3.18 |
| 60 m/min | 648 | 15,552 | ≈ 6.37 |
*One container ≈ 2,443 MWp. At 30 m/min the line fills ~3.18 boxes/day.
Production duration (for one 1 m line)
Time to print one 40’ HC (≈ 2,443 MWp)
| Line speed | Hours / container |
|---|---|
| 10 m/min | ≈ 22.62 h |
| 30 m/min | ≈ 7.54 h |
| 60 m/min | ≈ 3.77 h |
Weekly and monthly output (24/7)
| Speed | MWp / week | Containers / week | MWp / month (30 d.) | Containers / month |
|---|---|---|---|---|
| 10 m/min | ≈ 18.14 | ≈ 7.43 | ≈ 77.76 | ≈ 31.83 |
| 30 m/min | ≈ 54.43 | ≈ 22.28 | ≈ 233.28 | ≈ 95.49 |
| 60 m/min | ≈ 108.86 | ≈ 44.56 | ≈ 466.56 | ≈ 190.99 |
Stages (for one line @ 30 m/min)
- 1 MWp → ~3.09 hours.
- 10 MWp → ~1.29 days.
- 100 MWp → ~12.86 days.
- 600 MWp → ~77.16 days.
At 70% OEE one 1 m line @30 m/min ≈ ~2.0 GWp/year.; five lines ≈ ~10 GWp/year.
Send as a roll (optimal 5 m) — roll onto mega trailers, unroll the same day
Why 5 m? Wide enough for few seams, and narrow enough for road permits. At the port, we stitch five 1 m strips into a 5 m mother roll and roll it for transport.
5 m mega rolls (same thickness and core)
Assumptions: width 5.0 m, thickness 2.0 mm, core Ø 0.20 m, 180 W/m², 2.0 kg/m².
| Outer Ø | Length | Area | Nominal power | Mass | Discharge time @30 m/min |
|---|---|---|---|---|---|
| 2.30 m | ≈ 2,061.7 m | ≈ 10,308 m² | ≈ 1.856 MWp | ≈ 20.62 t | ≈ 68.7 min |
| 3.00 m | ≈ 3,518.6 m | ≈ 17,593 m² | ≈ 3.167 MWp | ≈ 35.19 t | ≈ 117.3 min |
| 4.00 m | ≈ 6,267.5 m | ≈ 31,337 m² | ≈ 5.641 MWp | ≈ 62.67 t | ≈ 208.9 min |
- Default mega-trailer: Ø 2.30 m (~20.6 t). One drum per ground level; connect to powered unwinding device and unwind within an hour.
- Breakbulk/Ro‑Ro: Ø 4.00 m (~62.7 t) for less frequent changes; heavy lifting required at port/site.
- Note: Containers are still ideal for 1 m rolls. 5 m drums — for roads/breakbulk.
Unwinding performance (5 m)
| Unwinding speed | MWp / val. | MWp / d. | Rolls/d. (Ø 2.30) |
|---|---|---|---|
| 15 m/min | 0,81 | 19,44 | ≈ 10.5 |
| 30 m/min | 1,62 | 38,88 | ≈ 21.0 |
Daily tonnage is determined by area, not roll size. At 30 m/min, ~432 t/d of laminate (2.0 kg/m²) is laid.
Mega-trailer method (by road)
- Sew/laminate near the port. Five 1 m strips → 5 m section with seam mains.
- Roll and load. Roll onto Ø 2.30 m drum; place on a low-bed with removable axles.
- Lead and connect. Wide load; connect the drum to the driven "pay-off" in the start zone.
- Unrolling process. 15–30 m/min; pressing rollers glue PSA tapes; edges follow the sealing seam.
- Cables and QC. Quick connections every 50–100 m to 1,500 VDC panels; vision/IR + IV test follows the train.
This is not a race — we just do it simply
We don't chase trophies. Speed simply comes when there are fewer parts and fewer decisions: unroll, press, seal, connect. That's all.
- Fewer steps → fewer delays.
- First, location. Sew/laminate at the port or inland; the factory is a set, not a cathedral.
- Energy the same day. Load onto trucks, unroll upon arrival, start counting kWh.
Sunny day output vs. coal that would need to be burned
On a clear day, "sun hours" Hsun ≈ 4–7. Energy on sunny days ≈ MWp × Hsun. To match this by burning coal requires ~1.14 lb/kWh.
Quick comparison (let's take Hsun=6)
| Object | Nominal power | Sunny day energy | Coal equivalent | Dump trucks* |
|---|---|---|---|---|
| One 5 m roll Ø 2.30 m | 1.856 MWp | ≈ 11.136 MWh | ≈ 6.35 short tons | ≈ 0.25 |
| One 40’ HC (36× 1 m rolls) | 2.443 MWp | ≈ 14.658 MWh | ≈ 8.36 short tons | ≈ 0.33 |
| One 5 m trailer, 1 day @30 m/min | 38.88 MWp/day | ≈ 233.28 MWh | ≈ 133.0 short tons | ≈ 5.3 |
| “Solar rise” 100 km × 5 m | ≈ 90 MWp | ≈ 540 MWh | ≈ 307.8 short tons | ≈ 12.3 |
| One 20 m trailer, 1 day @30 m/min | 155.52 MWp/day | ≈ 933.12 MWh | ≈ 531.9 short tons | ≈ 21.3 |
| Corridor 1,000 km × 20 m | ≈ 3.6 GWp | ≈ 21,600 MWh | ≈ 12,312 short tons | ≈ 492.5 |
*Large multi-dump trucks ≈ 25 short tons. Multiply energy and carbon by (Hsun/6) to other locations.
Ships, containers — and sometimes without them
When building locally, we don't always know how many containers will fit on the ship. Therefore, we keep two doors open.
A) Containers (when available)
- Rule of thumb: one 40’ HC ≈ 2.443 MWp (36× 1 m rolls).
- Ship "on a napkin": Ship MWp ≈ 2,443 × FEU; adjust for actual loading/weight.
B) First place (when boxes are missing or unknown)
- Sew near the port or internal base. Make 5 m sections from 1 m strips.
- Mega-trailers. Wrap on low-bed trailers; unwrap the same day at 15–30 m/min.
- Breakbulk/Ro‑Ro. For coastal sprints, transport larger drums and bypass containers.
Physics and material cost
Material intensity: ~2.0 kg/m² (without glass, without frames) → ~90 W/kg at 180 W/m².
Indicative material estimate (per m²)
| Layer | Mass | Notes | Physical minimum price* |
|---|---|---|---|
| Polymers (top layer, encapsulants, substrate) | ~1.6 kg | fluoropolymer + EVA/ionomer + PET/PO | 4–7 $ |
| Barrel package | <0.05 kg | AlOx/SiOx or metallized film | 0.5–1.5 $ |
| Conductors | ~0.08–0.15 kg | Cu/Al grid and busbars (minimize Ag) | 0.7–2.5 $ |
| Active package | <0.02 kg | thin film (perovskites/CIGS) | 0.8–3.0 $ |
| PSA + edge seals | ~0.2 kg | strip pattern + perimeter seam | 0.8–1.5 $ |
| Subtotal | ~2.0 kg | — | 7.8–15.0 $/ m² |
At 180 W/m² → material “floor” ~0.043–0.083 $/W. With wear, labor, energy, defects, QA, warranty: “factory gate” often ~0.15–0.30 $/W scale. Illustrative, not a commercial offer.
Physical “costs” we control
- Flat vs slope/tracking: −8–20% yield vs optimal slope (depends on latitude).
- Heat: tempco ~−0.2 to −0.35%/°C; matte coatings help.
- Dirt: in arid regions 3–8% without light cleaning; plan service lanes.
- Wind uplift: design for ~1–3 kPa gusts; patterned PSA + edge anchors/berms.
- Seams: the fewer the better; 5 m strips — the sweet spot.
Not small crumbs — but a real global factory
- Printing core: many 1 m R2R lines @30 m/min → ~2.0 GWp/year. per line (70% OEE).
- Port sewing centers: 1 m strips joined into 5 m sections; rolled for roads or breakbulk.
- Laying trailers: regional fleets unroll 15–30 m/min → ~19–39 MWp/d. each.
- Mass logistics: ~432 t/d. laminate per one trailer @30 m/min.
- Quality at speed: vision/IR, IV test, GNSS "as-built"; flying joints so no stops.
From amazing demo — to continent-scale gigawatts — without waiting for exceptional factories.
Will we have somewhere to use the electricity?
Yes — if we plan offtake as boldly as the "rollout". Build 2–10 MW blocks, group near substations and pair with flexible loads so midday watts don't stand idle.
Main consumers (pair from day one)
- Water: desalination and large-scale pumping (potential storage in canals/ponds).
- Agro-industry: cold chain, mills, oilseed pressing, irrigation.
- Materials: cement grinding, inert washing, clay calcination (electrified), brick drying.
- Molecules: H2 → ammonia/fertilizers or methanol; work hardest at midday.
- Data and communications: edge DCs, towers, rectifier loads.
- Transport: e-bus/e-truck depots; loading windows align with the sun.
Network strategy
- 1,500 V DC blocks → transformers to MV → substation ring → HV/HVDC corridor.
- Low storage, many loads: prioritize managed demand; add 1–2 hours of storage only when it increases value.
- Creative PPAs: co-locate industry; treat the corridor as an energy-industrial park.
Extension: 20 m mother section (breakbulk “mega roll”)
Where ports and corridors allow non-standard cargo, 20 m is even faster (fewer seams, fewer stops).
| Outer Ø | Length | Nominal power | Mass | Discharge time @30 m/min |
|---|---|---|---|---|
| 3.0 m | ≈ 3.52 km | ≈ 12.67 MWp | ≈ 140.7 t | ≈ 1.96 val. |
| 4.0 m | ≈ 6.27 km | ≈ 22.56 MWp | ≈ 250.7 t | ≈ 3.49 val. |
Heavy lifting and secure fastening at sea are needed. 5 m allows starting almost anywhere; 20 m — coastal sprint mode.
"On the envelope" — calculations you can do even in front of the mayor
- Sunny day energy: MWh ≈ MWp × Hsun (use 4–7).
- Carbon (short tons): ≈ 0.00057 × kWh → multiply by 0.57 for MWh.
- Dump trucks: short tons ÷ 25 (large road dump trucks).
- Laying speed (5 m): MWp/h ≈ 0.054 × speed (m/min) → 30 m/min ≈ 1.62 MWp/h.
- Laying speed (20 m): MWp/h ≈ 0.216 × speed (m/min) → 30 m/min ≈ 6.48 MWp/h.
Enough for real solutions — no calculators needed.
Calculated in advance: real roof
Warehouse: 100,000 ft² → 9,290 m²; allocate 70% for modules.
- Covered area: ≈ 6,503 m²
- Nominal power: ≈ 1.171 MWp (at 180 W/m²)
- Additional dead weight: ≈ 13.0 t (at 2.0 kg/m²)
- Annual energy (20% CF): ≈ 2,051 GWh
- Carbon equivalent / year: ≈ 1,169 short tons
Friendly (and funny) comparison
Nuclear energy: stoic marathon runner — slow until the first kWh, then very stable.
Rolling sun: energetic sprinter — operates this quarter already, kWh accumulates even before the opening ribbon. We love both; just really love arriving early.
Numbers are rounded and illustrative; check standards, wind, fire safety, ports, permits, and road rules for your own projects. No scripts are used on this page.