With the collaboration of Antonio Carlos Sil
In Brazil, solar energy is often celebrated as a symbol of the energy transition and a sustainable future. However, a topic that is still little discussed is gaining increasing relevance as the sector matures.
What happens to solar panels when they stop working? The answer lies in recycling, or rather, in the lack of a structured chain for it.
In an interview with Canal Solar, Everton Gois, electrical engineer and founding partner of Solar 55, one of the first Brazilian companies specializing in the recycling of photovoltaic modules, commented on the challenges and opportunities of a market that is still in its infancy in terms of solutions, but which is about to face a significant increase in the volume of waste.
An environmental time bomb.
According to Gois, the solar panel recycling It is still in an "embryonic" stage worldwide, and Brazil is no exception.
"Today, it is estimated that only about 10% of panels are actually being recycled and diverted from landfills. We estimate that the recycling percentage follows the national average for solid waste, which is around 4%," he explained.
While countries like the United States and, especially, the European Union have already implemented specific policies and ambitious recycling targets, such as the European directive that foresees up to 80% recycling of discarded panels, in Brazil, disposal still occurs in a disorganized manner.
According to Gois, a large portion of the discarded modules are still treated as ordinary scrap metal by local companies.
Data from IRENA (International Renewable Energy Agency) reveals that by 2030, Brazil is expected to accumulate between 3 and 8 tons of solar waste. Globally, the number could reach up to 80 million tons by 2050.
Gois warns, “It’s important to emphasize that this is still just the first step in disposal. The major tsunami of waste will occur between 2045 and 2055, when most of the modules currently in operation reach the end of their useful life of 25 to 30 years.”
When asked if a structured recycling chain already exists in Brazil, Gois was direct:
“We cannot yet speak of a structured supply chain. We are only in the first steps and the challenges are great, especially in logistics and in raising awareness among companies about the importance of environmentally sound disposal.”
He refers to the absence of specific regulations for the sector, although he points out that photovoltaic modules can be classified as electronic waste within the National Solid Waste Policy, which follows an environmental priority order of repair, preventive maintenance and, when necessary, evaluation for reuse before recycling.
Recycle or reuse?
Although reusing solar modules may seem like a more sustainable solution, Gois points out that this is not always a viable alternative.
"Cracks in the glass can create hot spots in the cells, compromising performance and, in extreme situations, even posing a fire risk due to overheating," he stated.
The engineer cited successful models in countries such as Germany and the United States, where private companies have led innovative initiatives.
He also highlighted the crucial role of the European WEEE (Waste Electrical and Electronic Equipment) Directive, which assigns legal responsibility to manufacturers for the end-of-life of equipment.
For Gois, recycling solar panels is not only an environmental obligation, but also a key piece in building a circular economy in renewable energies.
“The recycling of photovoltaic modules should be seen as a natural and necessary step within the solar market chain. Today, the sector focuses mainly on generation and expansion of installed capacity, but as the first parks begin to reach the end of their useful life cycle, the correct disposal of the modules becomes a central point to ensure the sustainability of the sector,” he added.
Regulation, responsibility and a sustainable future
International experience shows that well-defined regulatory frameworks can accelerate the development of sustainable solutions for the disposal of solar modules.
In the case of the European WEEE Directive, for example, ambitious targets are set: a minimum collection rate of 85% of equipment placed on the market and a minimum recovery and recycling rate of 80%.
According to experts, this type of regulation is essential to boost both technological innovation and the creation of a structured logistics chain.
"It's a model that can and should be adapted to the Brazilian reality," said Gois, highlighting that the country already has a legal framework that can be applied to the sector.
The National Solid Waste Policy (Law No. 12.305/2010) and Decree No. 10.240/2020 establish shared responsibility for the life cycle of products, including the need for reverse logistics for electronic and electrical items, a category in which photovoltaic modules can be classified.
PV panel recycling market will be worth US$2,7 billion by 2030
Despite this, the practice is still far from ideal. According to Gois, today the burden of disposal is unfairly falling on the end consumer, who faces not only logistical costs, but also a lack of clear guidelines and adequate collection points.
To change this scenario, he advocates for the effective engagement of manufacturers, integrators, and distributors.
"It is up to manufacturers, distributors, and integrators to structure and finance reverse logistics systems, including the creation of collection points, covering transportation costs, and ensuring proper final disposal," he emphasized.
Circular economy as a strategic opportunity
Far beyond an environmental demand, the recycling of photovoltaic modules is seen by professionals as a key element in integrating solar energy into the circular economy. According to Gois, this is achieved through three fundamental pillars:
- Extending the life cycle of materials: recovering aluminum, glass, and precious metals reduces the need to extract new natural resources, thus decreasing the sector's carbon footprint.
- Shared responsibility and efficient reverse logistics: the active participation of all actors in the chain, from manufacturer to consumer, is essential to ensure that waste returns to the production cycle.
- Promoting innovation and new business models: recycling can generate valuable secondary inputs for the photovoltaic industry itself, stimulate the creation of green jobs, and open up opportunities for reuse technologies.
End of the solar cycle
As the solar market matures in Brazil, the debate about the end-of-life of equipment needs to gain traction. For Gois, recycling should be seen as the final and essential link in the solar chain.
"Today, the sector is very focused on expanding installed capacity, but as the first parks begin to reach the end of their useful life cycle, the proper disposal of the modules becomes a central point to ensure the sustainability of the sector," he warned.
In addition to reducing environmental risks, adopting recycling and reverse logistics practices can strengthen the sector's credibility, attract investment, and open doors for exporting technologies and know-how in the circular economy.
Although solar panel recycling is still far from being a consolidated reality in Brazil, companies like Solar 55 are already working to transform this environmental challenge into an opportunity for innovation and sustainable development.
With plants in operation and a logistics chain under development, the company is taking the first steps to structure what could become, in the future, one of the pillars of the circular economy in the energy sector.
According to him, the challenges begin well before the actual recycling process. The logistics for collecting and transporting photovoltaic modules is one of the most complex stages of the entire process, especially in a country with continental dimensions like Brazil.
"Our strategy is to work with strategic logistics partners, which allows us to serve the entire national territory with operational and cost efficiency," he explained.
The company is also in dialogue with cooperatives, installers, and waste managers to establish regional partnerships that reduce costs and increase the reach of operations, a crucial step considering that the lack of collection points and technical support remains one of the sector's main shortcomings, as pointed out in the first text.
Critical operation and skilled labor
The process of recycling the modules begins with highly organized and meticulous steps. Gois explains that the operation involves handling heavy and large equipment, which requires specialized labor and infrastructure at the power plants.
After the modules arrive at the processing units, located in Juazeiro (BA) and Janaúba (MG), the dismantling process begins.
The junction boxes and aluminum frames are removed manually with the aid of machines, in a semi-automated line.
Next, the modules go through a fully automated line where the materials are separated into glass, silicon, metals, and polymers.
“This automation allows for greater efficiency, precision in sorting, and operational safety during processing. Transporting large volumes over shorter distances significantly reduces costs for the customer and makes the process more viable,” Gois added.
"Second life" before recycling
The management of the end-of-life of photovoltaic components was also a central theme in the debates held at Intersolar South America 2025, which took place in August at Expo Center Norte, in São Paulo (SP).
Laís Vidotto, New Business Manager at SunR, company specializing in the recycling of components for photovoltaic power plants.He emphasized that ensuring the sustainable disposal of waste and reintroducing it into the production chain contributes to making solar energy even more renewable.
"SunR is structured to meet the national demand for reverse logistics, serving both individuals and large companies," he explained.
The company's processing units are located in Valinhos (SP) and Montes Claros (MG), complemented by a sales office in Florianópolis (SC).
According to Laís, the solutions provided range from logistical planning and collection of photovoltaic modules to technical evaluation to determine the most appropriate course of action: reuse or recycling.
The company's experience, however, indicates that most of the waste today is premature. The organization reports that 99% of the material received is due to failures that occur before the end of its expected useful life.
The main factors driving immediate disposal include damage during transport, manufacturing defects, and severe weather events, such as the storm that mobilized an entire logistics operation in Paracatu, in southeastern Minas Gerais, to service the Boa Sorte Solar Complex, where approximately 46 MW of equipment capacity was lost.
Although requests for decommissioning plants at the end of their projected lifespan are starting to come in, reports Laís, other reasons have been recorded more frequently.
Repowering, which involves replacing modules, such as from single-sided to two-sided units, creates a contradictory situation where many components are sent to the end of their life cycle while still in good condition.
This is not an isolated observation, the expert points out. A study in Japan conducted with recycling companies showed that 67% of the components received were still suitable for continued operation.
The evaluation of 'second life' is a priority. In this model, a module that comes from a large power plant (GC/GD) can be tested and redirected to other contexts, such as residences or public lighting, extending its impact of clean energy generation and even generating social impact.
However, reuse must be done properly, ensuring quality and safety.
"For this, SunR conducts electrical tests and safety tests," describes the business manager.
The need for standardization is recognized by the company, which is involved in developing a standard to provide a basis for safe reuse in a "second life".
This focus on safety aims to prevent defective modules from being sent for reuse. As an example of the viability of this practice, Laís mentions a first case of "second life" monitored in Brazil, carried out by LABSOLAR, from UFSC (Federal University of Santa Catarina), where crystalline modules, which operated for more than 20 years after undergoing electrical tests, continue to generate clean energy in a social context.
When reuse is not feasible, the component is sent for recycling, where the goal is to recover the materials. The process aims to reintroduce aluminum and glass into the industry, closing the circular economy.
Following studies initiated in 2020, the company developed a 100% Brazilian machine for processing module components. This equipment is capable of recovering more than 90% of the photovoltaic panel, allowing the separation of aluminum, glass, cells, plastics, cables, and connectors.
Throughout its years of operation, SunR has contracted the recycling of approximately four thousand tons of modules, equivalent to one hundred and thirty thousand units. The company has carried out three hundred and fifty collections in twelve Brazilian states and is a partner of PV CYCLE, an organization specializing in the photovoltaic recycling sector internationally.
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An answer
This story about solar panels reaching the end of their lifespan at 25 or 30 years is a big lie!
What happens within that timeframe is the end of the warranty. The reality is that solar panels continue to produce energy for well over 30 years. At 30 years old, they still produce 80% of the energy they produced when new. I myself have panels that have been working continuously for over 30 years, and which have inferior technology compared to those of today. Modern panels with Topcom technology will reach 50 years producing, on average, half of their initial energy. This is why industries are still not concerned with recycling.