01 Performance Decline Despite Panels Appearing Intact
Project Overview
Location: Kansai region, Japan
Number of panels supplied: 25,200 units
Plant Capacity: Approx. 16MW
An issue was identified at a solar power plant located in the Kansai region.
At first glance, the panels appeared to be in excellent condition, with no visible cracks and minimal surface contamination. Externally, there were no apparent defects.
However.....
A significant decline in power output was confirmed, far exceeding the range normally expected under standard operating conditions.
The plant had been operational for only a short period, a stage during which substantial power degradation is generally uncommon.
In order to identify the root cause, the operator conducted a series of detailed investigations and ultimately concluded that the decline in output was due to manufacturing defects within the panels.
02 Panels Discontinued?! — Replacement panels from GBP
After contacting the manufacturer and investigating, the issue was confirmed as a product defect. As the panels were still under warranty, replacement was eligible.
However, the specific model had been discontinued, making direct replacement with identical units impossible.
While the manufacturer faced challenges in providing a solution, our company’s replacement panels—designed to match the discontinued model in dimensions, mounting points, and outputand power output (with cumulative sales reaching 300,000 units by July 2025), leading to its selection for the replacement.
In addition, our extensive track record, professional expertise in design and construction, the capability to provide one-stop service from product to installation, and comprehensive after-sales support were highly valued.
Based on this credentials and reliability, the manufacturer approved GBP’s compatible panels as the official warranty replacement.The power plant operator also recognized GBP's technical capabilities and product quality, enabling the smooth implementation of this replacement.
03 Achieving Both Cost Reduction and Shadow Mitigation
In addition, our company offers customized panels with enhanced power output.
For existing power plants, it is generally required that the total DC capacity remains unchanged. By utilizing panels with the same dimensions but higher per-unit output, the number of installations can be reduced.
This approach provides the following two key benefits:
◆ Increased Output While Controlling Costs
By increasing the output of each panel and reducing the total number of installations, not only are the costs of the panels themselves lowered, but transportation and installation expenses are also reduced.
◆ Optimized Layout to Mitigate Shadowing
Over time, factors such as the growth of surrounding trees may increase shaded areas. By strategically reducing the number of panels, installations can avoid areas prone to shading, ensuring optimal energy generation tailored to site-specific conditions.
04 Appearance Does Not Guarantee Optimal Performance
"Even if a panel appears visually pristine, its power output may still fall below expectations."
In this case study, panels that looked to be in excellent condition were found to underperform due to inherent manufacturing defects.
When replacing these panels, selecting compatible units with identical dimensions but higher output enabled the plant to restore its designed generation capacity efficiently while controlling replacement costs.
▶ Explore GBPダイレクト
Our e-commerce platform GBP Direct offers over 400 compatible panel models ranging from 245W to 445W. Clients can efficiently identify and procure the most suitable compatible panels based on output or model number, with single-unit orders fully supported.
At GBP, we provide comprehensive support, from recommending the most suitable compatible panels for existing installations, to site-specific layout design, installation, and after-sales service. For inquiries regarding equipment assessment or panel upgrades, please feel free to contact us via the form below.
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