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The cost of creating solar cells
At the Always On Venture Summit in Half Moon Bay, Calif., a panel of solar energy executives debates whether or not silicon prices will fall as the industry matures. While they all think margins will narrow, they disagree on whether there will be an industry wide shakeout, or if the polysilicon and silicon wafer markets will move up and down separately. Panelists include Suvi Sharma, CEO of Solaria, and Peter Nieh, managing director of Lightspeed Venture Partners. The moderator is David Chen, managing director of Morgan Stanley.
Music
Male Speaker: A pretty hot debate right now, just love
your perspective on what's going on in the silicone
market.
Male Speaker: Well, the first thing I think that we're
seeing is a compression of the margins, and the margins
have been way too high. You know, some of the silicon
-- the reason why there's so many people trying to get
into silicon refining is the gross margins for some of
the leaders like MEMC, REMC, have been up as high as
80%, which for, you know, turning some sand into
purified silicon is way too high. So that's going to
get compressed. The -- I think we've seen, you know,
depending on different counts, 80 to 150 new silicon
refiners coming on line. My estimation, which is just a
rough ballpark estimation is 80% of those will not
success or survive the current economic climate.
Probably half of those wouldn't have survived anyway.
It is harder to do than it sounds. So we're going to
see compression of the margins, but we are seeing growth
in silicon supply. I -- I don't know if we are going to
be in oversupply next year. I know different analysts
-- some analysts are convinced that we're going to be,
but it's a little bit hard to say because we don't
really know exactly what the demand environment is like,
we don't know what the supply environment -- environment
is like. But overall, I just see Inaudible falling,
they already are. You know, we're seeing ASP drop from
2008, 2009, which we did not see from 2007 to 2008,
actually prices went up. So in my view what happened in
the last three years, we're collapsing very quickly into
2009 as this market matures in the economic climate it's
a lot worse. So margin compression is really what I see
happening. And there is -- that's healthy. I think
there's been too much margin. And so when that happens,
there are players in the middle that will get squeezed
and will go out of business or get consolidated or
acquired, and I do see that happening in 2009. Again,
the analysts forecast an industry shake-up. Again, I'm
not con convinced there's a shake-out, I just think
there's going to be a clean out of the second tier and
third tier players, that at the end of the day have a
factory and went public with a factory. And that's not
a sustainable, competitive advantage. That's not a
sustainable business. But the leaders, and you know,
some of the leaders, you know, Inaudible some power, Q
cells, Inaudible these are very strong companies with
very strong management teams with very good customer
base, diversified -- they're going to be -- typically in
crisis situations the strong get stronger and the weak
get weaker, and that's what I see happening. But
overall, margins getting compressed, which I think is a
healthy thing for the industry.
Male Speaker: Right. Inaudible --
Male Speaker: I've got some comments on that. I think
the margins that you were talking about were really on
the poly silicon side. That you know, poly silicon was
fetching close to I think $400 kilogram on the spot
market. So you're going to get huge margins there. But
if you look at a panel and if you breakdown the costs,
the poly silicon, and I'm excludeing from this the
value-add that you do to the poly silicon, such as
wafering, is ballpark 30% of the cost of a panel. And
so it's 15% of the cost of, again, these are rough
numbers, the fully installed cost of a panel. So even
if you took that poly silicon price to zero, there's
only so much cost you can take out of your panel. So
I'm more of the mind that -- by a way a lot of the
manufacturers, the better ones, the ones that have been
around longer, have had Ford contracts on poly silicon,
which are clearly not at $400. They've been, you know,
$80, $60. Long term, you know, the costs of producing
poly silicon are roughly around $40 per kilogram. So if
you give those guys a fair margin, say poly silicon ends
up being 50 to $60 per kilogram, somewhere in that
range, there's only so much you can take out of cost
that, and the gross margins of your typical silicon
panel manufacturers are not that high. Sun Power's are
somewhat higher, but they have a lots of cost, actually,
in their system. But typically, you know, they're
somewhere between 20, 25% gross margin. And I don't
think, you know, I think most companies are pretty
rationally economically in that if you're producing and
you're not making any gross margin, you're not going to
produce -- you're just going to shut down factories. So
I guess what I'm trying to say is there's only so much
in the crystal and silicon market where you can compress
margins and still stay in business. And so I -- I do
think ASPs will decline, but you know I think people
have overreacted. I have seen some analyst reports that
talk about 40%, 50% type declines in the next year. I
think companies will just shut down factories. What
you're going to see is just this big supply correction.
And so prices are not going to fall by that much. I
think it's -- I'd be thinking closer to 20% declines in
terms of ASPs over the next year, as opposed to 40 or
50%.
Male Speaker: Just a couple comments on that. I agree
-- that I would say 15 to 20% manual ASP declines
from '08 to '09, and that's, you know, in terms of
negotiations we're doing on module supply contracts,
that's what we're seeing. One thing I would say a
little bit different, I don't think the margin -- the
high margin level is only at the poly silicon level. It
is at the Inaudible level and at the cell level. So
there are many wafer manufacturers, for example in
China, who have bought standard wafering equipment and
earning 37 to 38% gross margin. That is very high.
Inaudible there are some manufacturers who have bought
standard equipment from Europe, installed it, running
it, at 30 to 33% gross margins. In a mature industry,
that would not happen. You know, you should see at the
most I would say 20 -- I mean, to me we will settle down
in those areas at 20%. So I agree that the largest
portion is in the poly silicon side, and a lot of that
is because of spot market. So as that goes away that
was compress. But I do see it also on the wafer and
commodity cell prices. The margins have been very high
for a -- for a very, very commoditized process. If
you're adding differentiation or value or efficiency,
things like that, that's how I think you'll earn a
higher margin level than the 15 to 20% as this industry
matures. But today for standard commodity,
15-and-a-half percent efficiency sells. Equipment no
one can buy, install, run, you know, and part of the
reason they're earning those gross margins is because
they have access to poly silicon. And that's what --
that's what I see starting to change and shift and
normalize in the industry.
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