MiniTec has developed an entirely new production model for collector production. With their experience from photovoltaic module production, they have developed and certified new solar collectors. At the same time, production was standardized and optimized for these high-performance collectors. MiniTec's new SolarThermal Competence Centre (STCC) supports collector manufacturers from planning and setup of the production facility through certification and production start.


Schönenberg-Kübelberg, March 2010 – About half of the total energy consumption of the EU is used to generate heat or for cooling. The greater part of the power needed is produced from fossil fuel or nuclear power. Only by using of renewable energy sources will it be possible to remain equally comfortable while significantly reducing the release of gases harmful to the climate and preventing the consumption of material reserves. There has long since been a growth market in this area, but there are still many risks for the players in it. On the one hand, manufacturers of solar facilities are dependent on grants whose availability is more and more difficult to foresee. And on the other hand the fabrication processes must be more effective and thus more cost-effective, while still being subject to numerous constraints.

Innovative automation solutions and – especially – refined assembly processes are in demand. MiniTec has been a leading provider of innovative, efficient solutions in this area for over twenty years. For 15 years, this German company has also actively pursued the development of production facilities for photovoltaic modules. Many developments from this area can be transferred to the processes of manufacture of solar collectors for heat generation. "In contrast with photovoltaics, most collector manufacturers are still working on the principles of industrial fabrication," says Bernhard Bauer, founder and CEO of MiniTec GmbH & Co. KG. Production in one-off fabrication or very small series also makes products more expensive, and often causes problems with quality as well. So the manufacture of solar thermal systems must be optimized for permanent acceptance and cost-effective production. One condition for this is greater standardization of components for collectors. Fabrication must also be reorganized on the model of the automobile industry for rational series production at top quality.

Optimized collector production

These are the requirements for the new SolarThermal Competence Centre (STCC) at MiniTec in Waldmohr. Since moving into the attractive new company facilities in Schönenberg-Kübelberg (Pfalz) in 2009, MiniTec has used the production facilities freed up in Waldmohr for the construction of a production line for the latest generation of flat solar thermal collectors. The new production line was designed as a competence centre for solar production. The goal of the centre is to provide customers with practical experience in collector fabrication and to support the continual improvement of assembly methods based on empirical evidence.

Experience tells them that the development of the new solar collector will take at least two years. This time is needed to design the collector, develop individual parts, produce a prototype, and certify the final product. The certificate requires a series of time-consuming tests, without which the collector may not be installed. Moreover, production facilities must be procured and ready to operate by that time, in order to produce the collectors to be tested. And then the product changes resulting from testing often lead to entirely different requirements for the production facilities, which can have expensive consequences. Significant funds are needed to finance the period from development to certification.

Simplified production start

MiniTec recognized all these problems and developed an entirely new model for collector production. With their experience from photovoltaic module production, they have developed and certified new solar collectors. At the same time, production facilities were standardized and optimized for these high-performance collectors. Producers who want to start manufacturing solar collectors can obtain an unrestricted licence for a certified collector from MiniTec, confirmation of parts availability, and a tested production facility with the latest state of the art.

The setup of a production line for collectors takes about nine months. During that time, the client can place employees in the STCC for training and produce the first collectors under their own logo, to be used for marketing and market introduction. Like all MiniTec production facilities, the assembly line for solar collectors is built on a modular basis. Newcomers to the market can operate the line manually to start production of about 100 units per day. If necessary, the facility can then be upgraded as far as fully automated production for the manufacture of up to 1,000 collectors per working day.

The collectors are assembled on workpiece carriers that are automatically transported on an FMS conveyor to machining centres integrated into the line. The absorbers are manufactured on a laser welding system (LWS) in a parallel process. This system welds copper tubing at a speed of about 15 m/min onto the aluminium absorber area, which has a highly selective coating. This combination of materials has significant cost and weight advantages over the conventional Cu/Cu- absorbers. Fourteen LWS systems are already in use, with great success.

For all preparatory processes such as pipe preparation, production of harps and meanders, leak testing, and straightening systems, stations working in parallel are available so that the manufacturer can operate and control all work steps internally.

MiniTec has developed an entirely new production model for collector production. With their experience from photovoltaic module production, they have developed and certified new solar collectors. At the same time, production was standardized and optimized for these high-performance collectors. MiniTec's new SolarThermal Competence Centre (STCC) supports collector manufacturers from planning and setup of the production facility through certification and production start.


Schönenberg-Kübelberg, March 2010 – About half of the total energy consumption of the EU is used to generate heat or for cooling. The greater part of the power needed is produced from fossil fuel or nuclear power. Only by using of renewable energy sources will it be possible to remain equally comfortable while significantly reducing the release of gases harmful to the climate and preventing the consumption of material reserves. There has long since been a growth market in this area, but there are still many risks for the players in it. On the one hand, manufacturers of solar facilities are dependent on grants whose availability is more and more difficult to foresee. And on the other hand the fabrication processes must be more effective and thus more cost-effective, while still being subject to numerous constraints.

Innovative automation solutions and – especially – refined assembly processes are in demand. MiniTec has been a leading provider of innovative, efficient solutions in this area for over twenty years. For 15 years, this German company has also actively pursued the development of production facilities for photovoltaic modules. Many developments from this area can be transferred to the processes of manufacture of solar collectors for heat generation. "In contrast with photovoltaics, most collector manufacturers are still working on the principles of industrial fabrication," says Bernhard Bauer, founder and CEO of MiniTec GmbH & Co. KG. Production in one-off fabrication or very small series also makes products more expensive, and often causes problems with quality as well. So the manufacture of solar thermal systems must be optimized for permanent acceptance and cost-effective production. One condition for this is greater standardization of components for collectors. Fabrication must also be reorganized on the model of the automobile industry for rational series production at top quality.

Optimized collector production

These are the requirements for the new SolarThermal Competence Centre (STCC) at MiniTec in Waldmohr. Since moving into the attractive new company facilities in Schönenberg-Kübelberg (Pfalz) in 2009, MiniTec has used the production facilities freed up in Waldmohr for the construction of a production line for the latest generation of flat solar thermal collectors. The new production line was designed as a competence centre for solar production. The goal of the centre is to provide customers with practical experience in collector fabrication and to support the continual improvement of assembly methods based on empirical evidence.

Experience tells them that the development of the new solar collector will take at least two years. This time is needed to design the collector, develop individual parts, produce a prototype, and certify the final product. The certificate requires a series of time-consuming tests, without which the collector may not be installed. Moreover, production facilities must be procured and ready to operate by that time, in order to produce the collectors to be tested. And then the product changes resulting from testing often lead to entirely different requirements for the production facilities, which can have expensive consequences. Significant funds are needed to finance the period from development to certification.

Simplified production start

MiniTec recognized all these problems and developed an entirely new model for collector production. With their experience from photovoltaic module production, they have developed and certified new solar collectors. At the same time, production facilities were standardized and optimized for these high-performance collectors. Producers who want to start manufacturing solar collectors can obtain an unrestricted licence for a certified collector from MiniTec, confirmation of parts availability, and a tested production facility with the latest state of the art.

The setup of a production line for collectors takes about nine months. During that time, the client can place employees in the STCC for training and produce the first collectors under their own logo, to be used for marketing and market introduction. Like all MiniTec production facilities, the assembly line for solar collectors is built on a modular basis. Newcomers to the market can operate the line manually to start production of about 100 units per day. If necessary, the facility can then be upgraded as far as fully automated production for the manufacture of up to 1,000 collectors per working day.

The collectors are assembled on workpiece carriers that are automatically transported on an FMS conveyor to machining centres integrated into the line. The absorbers are manufactured on a laser welding system (LWS) in a parallel process. This system welds copper tubing at a speed of about 15 m/min onto the aluminium absorber area, which has a highly selective coating. This combination of materials has significant cost and weight advantages over the conventional Cu/Cu- absorbers. Fourteen LWS systems are already in use, with great success.

For all preparatory processes such as pipe preparation, production of harps and meanders, leak testing, and straightening systems, stations working in parallel are available so that the manufacturer can operate and control all work steps internally.