Voltiris: a successful collaboration that demonstrates our capabilities and expertise in design and manufacturing

Voltiris is a Swiss start-up that develops innovative solar modules for greenhouses, enabling the generation of renewable electricity without affecting crop yields. The collaboration with Teknia, led by Manuel Revuelto, has not only made a decisive contribution to improving the initial product design, but has also made it viable from a mass production perspective. Teknia, for its part, has demonstrated its manufacturing and innovation capabilities in sectors beyond the automotive industry.

How did the collaboration between Teknia and Voltiris come about? What does the project involve?

We were put in touch through the Solar Energy Institute at the Polytechnic University of Madrid, with whom Voltiris was working on developing the solution, and thanks to our reputation in other projects, they recommended Teknia as a design and manufacturing partner. Voltiris specialises in manufacturing a very specific type of solar tracker that reflects part of the solar radiation onto a photovoltaic panel, converting it into electricity, whilst allowing useful light to reach the crops for photosynthesis without affecting their yield. Teknia took on the challenge of redesigning the product, building on the original, to make it scalable from an industrial perspective.

And how did we do it?

The key was reducing the overall complexity, understood as the number of different parts. An advanced trigonometric study was carried out to generate contact interfaces that, in the previous design, were all different from one another. Despite the specific characteristics of each of the six mirrors in the assembly, we have managed to ensure that a single design meets the requirements of all six parts. I was personally very committed to achieving this because it was a key point. And not only that, but having contact surfaces between them allows the mirrors themselves to function as structural components and be self-supporting. Through this design, we have managed to reduce an assembly that originally consisted of 16 different parts to just 3, simplifying the list of materials by more than 80%. This means lower production costs, reduced structural weight, a smaller environmental footprint, and savings in assembly and logistics, amongst other benefits. We have also carried out mechanical simulations of the product we designed to ensure it met the necessary stress requirements and to validate the final prototype. Furthermore, we have selected the manufacturing technologies, process design, industrialisation and subsequent production. Our TCI has also played a key role in technical and commercial coordination and accelerating the go-to-market process.

What technological capabilities and manufacturing expertise at Teknia will make the manufacture of this product possible?

Teknia’s knowledge and production capabilities in plastic injection moulding technology have been fundamental. The tolerances required for a part with this function are very tight, and are combined with a need for stable performance at high humidity and temperature. Conventional injection moulding methods can generate internal stresses in the plastic, so these had to be ruled out in order to devise an injection moulding method that minimises these stresses.

Furthermore, the mirror effect is achieved using a high-tech, 0.08 mm semi-transparent film onto which the transparent plastic is overmoulded. Precision is of the utmost importance, as the cut and position of this film will determine the efficiency of light concentration on the photovoltaic panel. This project has enabled us to acquire and apply specific knowledge that we had not previously worked with; due to the specific nature of the product, we had never before carried out plastic injection moulding onto this type of film, thereby expanding our expertise.

How does this project strengthen Teknia’s position as a multi-sector manufacturing partner? 

It is a clear success story that demonstrates we hold a unique position in the European industry to bring any industrial production project to fruition, starting from the concept phase.

What lessons have you learnt from the experience?

Lessons learnt… many, in addition to new plastic injection moulding techniques and demonstrating our capabilities. I believe the project’s success validates the operating model of the Teknia Centre of Innovation (TCI), where commercial and engineering development is carried out at corporate level, before transferring the project to the plant for industrialisation. In this case, we have worked hand in hand with our Teknia Uherský Brod plant (Czech Republic). Our partner, Voltiris, is very satisfied with the collaboration and a solid partnership has been forged. On a personal level, it has been both a challenge and a source of satisfaction to be part of the project.

How does this Voltiris and Teknia project contribute to sustainability?

The project demonstrates a tangible impact on reducing emissions, energy efficiency and the competitiveness of the agro-industrial sector. These solar modules can cover up to 65% of the greenhouse’s energy demand. The reflector is the bulkiest and most expensive part of the system. Making the production of this system economically viable for large-scale production is what determines whether or not this method of harnessing sunlight is scalable. And if it is, we have proven it.