The latest report from the International Energy Agency’s (IEA) Photovoltaic Power Systems Program (PVPS) says that second-life PV modules have the potential to reduce waste and increase the value of solar energy, but their market today remains underdeveloped and requires advances in technical qualifications, scalable reuse infrastructure and supporting policy frameworks.
The photovoltaic industry must introduce supportive policy frameworks for second-hand PV modules to prevent the market from remaining niche and underdeveloped, according to a new report from IEA-PVPS.
The Task 13 report explains that while repairing PV modules, by addressing issues such as defective solder joints, cracked backsheets or junction box issues, is technically feasible, such repairs are often labor-intensive, costly and difficult to scale without automation.
According to the report, the second-life PV module market remains fragmented as a result, exacerbated by a lack of harmonized qualification criteria, standardized testing protocols and repair guidelines.
The report’s authors recommend rapid IEC-based technical specifications for the requalification and safety of reused modules, introduce financial instruments to close the cost gap between new and second-hand modules and batteries, and support investments in automated test hubs and logistics networks.
The report adds that automated test systems capable of IV characterization, electroluminescence imaging and insulation resistance testing are critical to providing a scalable path for second-life modules. “This approach enables efficient division into ‘reuse’, ‘repair’ or ‘recycle’ streams, minimizing labor costs and ensuring greater consistency,” the report explains. “Advances in aerial inspection, AI-based diagnostics and mobile testing labs can further reduce costs and risks while increasing throughput.”
Case studies highlighted in the report show that certain defects, such as bypass diode defects, can achieve a recovery rate of more than 90%, while modules with systemic solder defects had a success rate of only 10% to 15%. This leads to the conclusion that repairs are best reserved for specific contexts, such as remote areas or where logistics make replacement prohibitively expensive.
The report concludes that pilot projects confirm that second-hand PV and battery systems can “deliver tangible benefits in energy autonomy, reduced emissions and protection against electricity price volatility.”
“However, they also underline persistent challenges: the technical compatibility of heterogeneous module batches, the changing requirements for network compliance and the limited economic benefit of second-life batteries compared to new ones,” the report adds. “These experiences highlight the need for robust system integration guidelines and regulatory flexibility to enable broader adoption.”
Stephan Padlewski, founder of France-based solar panel maintenance service DOTSun, explains pv magazine The market opportunity for second-life PV modules in the EU already extends to the gigawatt scale and is growing rapidly as installed assets in Europe continue to age.
He added that extending the operational life of PV panels within a maturing second-life market would not only provide significant benefits in all areas of renewable energy, but also strengthen the regional PV ecosystem, gain significant expertise and regional value-added activities, improve the EU’s resilience and reduce over-dependence on imported products.
“Buying new panels for €0.10/W may sound attractive, but repowering means rebuilding the entire factory – including mounting systems, cabling and inverters,” says Padlewski. “In that context, repair becomes very competitive and systems can reach their full operational life without unnecessary waste.”
Padlewski added that the development of a market for second life products will require a coherent and stronger regulatory framework at EU level that will actively supports the reuse of panels on a secondary market.
“The EU market should certainly consider the reuse of modules that have been retired midway or even at the end of their service life – provided they continue to perform sufficiently well and continue to meet electrical integrity requirements after repair and retesting,” he said. “But today there is no incentive for reuse, despite the clear environmental and economic benefits.”
Padlewski also suggested that new testing protocols and quality assurance standards should be established prior to any panel reuse, with additional clarification on warranty ownership.
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