Solar panels are built to last 20–30 years, but when they reach the end of their life, the frames and components can still be repurposed. Recycling old solar panels isn’t just about responsible disposal—it’s about recovering valuable materials that can be re-used across multiple industries.
In this guide, we break down what’s inside an old solar frame, how it’s recovered, what it can be used for, and the approximate yield you can expect from each material.
Aluminium – Strong, Lightweight, and Infinitely Recyclable
Solar panels are surrounded by a sturdy aluminium frame to protect the glass and internal components.
Recovery Process:
During recycling, the frame is removed manually or mechanically, then sent to metal recyclers for shredding and smelting.
Potential Uses:
- New solar panel frames
- Window and door frames
- Construction materials
- Automotive and aerospace parts
The aluminium frame typically accounts for 10–15% of the total solar panel weight. From a 20kg panel, that’s around 2–3kg of recoverable aluminium.
Glass – The Heaviest Component
A tough, tempered glass sheet covers the solar cells, protecting them from weather, impact, and environmental damage.
Recovery Process:
The tempered glass layer on top of the panel is carefully separated from the other materials. It’s then crushed and cleaned to remove any residues.
Potential Uses:
- New glass products
- Fibreglass insulation
- Aggregate in construction materials
- Tiles and decorative surfaces
Glass makes up 60–70% of a solar panel’s total weight—that’s around 12–14kg from a standard 20kg panel.
Silicon - The Energy-Producing Heart
Thin silicon wafers inside the panel form the photovoltaic cells that convert sunlight into electricity.
Recovery Process:
The silicon wafers inside the panel’s cells are separated and cleaned to remove adhesives, coatings, and other contaminants. While this is more complex than metal or glass recovery, the end product is highly valuable.
Potential Uses:
- New solar cells and panels
- Electronics manufacturing (chips, semiconductors)
- Research and development for advanced photovoltaic tech
Silicon typically makes up 3–5% of a panel’s weight, meaning 0.6–1kg per panel.
Read more about our silicon recycling process here
Wiring – Copper and Other Conductive Metals
Copper and silver wiring within the panel connects the cells, carrying the generated electricity to the output terminals.
Recovery Process:
The wiring that connects the solar cells is stripped out and sorted. Copper and silver traces are recovered through mechanical and chemical processes, depending on the recycling facility’s capabilities.
Potential Uses:
- Electrical wiring and cables
- Electronic components
- Conductive materials in manufacturing
Wiring accounts for a small fraction of weight—around 1–3%, or 0.2–0.6kg of copper and silver per panel.
Other Materials – Plastics, Sealants, and Encapsulants
Layers of plastic encapsulants and back-sheets seal and protect the panel’s internal components from moisture and mechanical stress.
Recovery Process:
Encapsulants and back-sheet plastics are separated during the dismantling process. While they are less valuable than metals or glass, some facilities can process them into secondary plastic materials.
Potential Uses:
- Composite building materials
- Plastic pellets for injection moulding
- Road surfacing additives
Plastics and encapsulants make up around 5–10% of the panel’s weight, or 1–2kg per panel.
Why Material Recovery Matters
Recovering materials from old solar frames isn’t just about avoiding landfill – it’s about closing the loop.
Aluminium can be recycled endlessly without losing quality, glass can be transformed into new products, and silicon can go straight back into making more renewable energy technology.
For solar installers and operators, understanding what’s recovered helps you make informed recycling choices, stay compliant with waste regulations, and show your customers your commitment to sustainability.
