Tresca to Helm Spain’s 20-GW Wafer Gigafactory

• Tresca will steer Sunwafes’ 20‑GW Spanish solar‑wafer gigafactory, fast‑tracking onshored production, greener processes and skilled jobs—anchoring EU resilience from pilot to scale with n‑type roadmaps.

Spanish engineering firm Tresca has been appointed owner’s engineer for Sunwafes’ planned 20‑GW solar‑wafer gigafactory in Spain. Tresca will steer design, grid connection, commissioning, safety, and performance testing, while validating process flows, utility sizing (ultra‑pure water, gases, HVAC, power), construction sequencing, vendor selection, permitting, and environmental compliance, including waste treatment and resource‑intensity reductions.

The project aligns with Europe’s onshoring push, shortening lead times, improving traceability, and supporting n‑type roadmaps (TOPCon now, heterojunction/back‑contact later). Spain stands to gain skilled jobs and a supplier ecosystem, with renewables‑backed power and heat recovery cutting costs. A phased pilot‑to‑scale ramp is planned; successful execution could anchor a more resilient EU solar stack.

How will Tresca de-risk Sunwafes’ 20‑GW Spanish wafer gigafactory and EU onshoring?

• Acts as owner’s engineer to translate Sunwafes’ roadmap into bankable designs with clear performance guarantees, reducing lender and insurer risk.
• Runs front‑end loading (FEL) and constructability reviews to lock scope, budget, and schedule before procurement, minimizing change orders.
• Validates wafer process flow and tool list via pilot-line trials, FAT/SAT protocols, and yield targets, de‑risking the ramp from demo to 20 GW.
• Optimizes utilities (UPW, gases, vacuum, HVAC, power) and redundancy, cutting bottlenecks and single points of failure that jeopardize uptime.
• Implements digital twin/MES/SPC with inline metrology for early defect detection, stabilizing yields and shortening learning curves.
• Leads vendor prequalification and dual‑sourcing strategy for critical tools, spares, and consumables, insulating against supply shocks.
• Structures EPC/EPCM packages and incentive contracts tied to throughput, availability, and specific energy/water intensity.
• Conducts HAZOP/SIL and safety culture programs; designs abatement for process gases and kerf/swarf management to meet strict EU norms.
• Manages permitting, EIA, and compliance with REACH, Seveso, and industrial emissions rules, accelerating approvals and avoiding redesign.
• Engineers closed‑loop water and heat‑recovery systems to cut OPEX and improve ESG scores, supporting green‑premium offtake.
• Secures grid capacity, redundancy, and power‑quality solutions; aligns with PPAs and hedging to stabilize electricity costs over the ramp.
• Aligns specs with EU standards (CE, Machinery, Ecodesign) and traceability frameworks, easing conformity assessment and audits.
• Prepares life‑cycle carbon and EPD documentation to meet EU buyer requirements and potential eco‑design thresholds.
• Builds workforce pipeline (operators, maintenance, process engineers) with standardized SOPs and training, reducing ramp slippage.
• Plans logistics, site layout, and phased construction sequencing to bring early modules online while later bays are built.
• Establishes QA/QC regimes and wafer‑grade certification with third parties, increasing bankability for downstream cell/module buyers.
• Designs take‑back/recycling for wafers/swarf and chemical loops, supporting circularity and compliance with extended producer rules.
• Supports grant and state‑aid applications (e.g., NZIA/IPCEI), de‑risking capex and anchoring EU supply‑chain localization.
• Coordinates with upstream polysilicon/ingot suppliers and downstream cell makers in Europe to lock volumes and balance specs, reducing market risk.
• Develops contingency plans for tool delays, energy curtailment, and regulatory changes, keeping the onshoring timeline on track.