Illuminate USA, a leading solar panel manufacturer based in Pataskala, Ohio, has entered into a five-year agreement with Solarcycle to source recycled solar glass. Under the deal, Solarcycle will supply enough glass to support the production of 3 GW of solar panels each year, totaling 15 GW over the contract period.
Operating from its 1.1 million-square-foot facility, Illuminate USA specializes in producing bifacial solar panels. This long-term partnership positions the company as the largest customer for Solarcycle’s upcoming solar glass manufacturing plant in Cedartown, Georgia. The facility will produce glass made from recycled materials recovered from retired solar panels, reinforcing both companies’ commitment to sustainable manufacturing.
Solarcycle aims to begin initial deliveries from the new Georgia plant by early 2028, marking a significant step toward building a domestic, circular supply chain for solar materials in the United States.
Illuminate USA is a U.S.-based joint venture between Invenergy—an American renewable energy company—and LONGi, a global solar manufacturing leader. Located at 3600 Etna Parkway within the Red Chip Farms development of Pataskala Corporate Park, the company operates in what is now the largest single-site solar panel manufacturing facility in North America.
The facility spans approximately 1.1 million square feet and is equipped to produce up to 5 GW of solar modules annually—roughly 9.2 million panels—enough to power around 1 million homes.
Construction & Build-Out Highlights
Initially a speculative structure, the facility also houses critical support infrastructure—laboratories, cleanrooms, break rooms, mechanical and packaging areas, and a destructive testing lab—key for quality control and R&D. Illuminate USA’s robust system architecture includes medium-voltage 34.5 kV distribution, high-power compressors (3,200 HP), process cooling water systems (660 tons), and safe exhaust filtration via a regenerative thermal oxidizer.
Industrial Production Process
Production commenced in February 2024, when the first panels began rolling off the lines. To date, more than 475 employees have been hired, with projections exceeding 1,000 full-time jobs as operations ramp up. In the first six months, the company celebrated the hire of its 1,000th “Illuminator” and the production of its one-millionth solar panel—a remarkable milestone for Illuminate USA.
Production involves eight parallel assembly lines, each spanning nearly 1,000 feet, with a curved layout that transports each panel an estimated 1,775 feet during assembly. Completing a panel takes roughly six hours, and at full capacity, the plant can produce over 1,000 panels per hour.
Rolling Out Domestic Materials & Sustainable Supply Chain
In a continued push for U.S.-based sourcing, Illuminate USA finalized a five-year agreement with recycled-glass supplier Solarcycle. This deal will deliver 3 GW of domestically produced solar glass annually—15 GW total over five years—enhancing the sustainable, circular supply chain of solar materials.
Plans for an ultra modern solar-grade polysilicon manufacturing facility in Phipps Bend, Tennessee will e able to offer the critical raw material for such a plant that needs the ultra-pure form of silicon that serves as the foundation for over 90% of the world’s solar panels.
Economic & Regional Impact
The project represents over $600 million in total investment when accounting for equipment, raw materials, staffing, and related infrastructure. It has quickly become Pataskala’s largest employer, bringing advanced manufacturing careers and significant economic uplift to Licking County.
Strategic Significance
Illuminate USA plays a pivotal role in bolstering U.S. solar manufacturing capacity, aligning with federal goals to reshore clean energy supply chains and foster energy independence. Its operation underscores Ohio’s emergence as a premier solar manufacturing hub.
Reported on 26th March 2023 – A look but while constructon was underway and how we reported it:
Plans are underway for the construction of a US$ 200M solar panel manufacturing plant in Ohio. The facility is set to be built by Invenergy. These plans come as the market for polycrystalline photovoltaic solar equipment expands in the United States.
A 5-GW annual capacity is planned for the 1.1 million square foot plant. According to JobsOhio, this is over half the capacity of all utility-scale solar installations made in the United States last year. April is the anticipated beginning of construction. 150 union construction jobs should be supported by the project. Invernergy is one of the largest solar power developers in the USA with an installed capacity of 7GW.
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According to JobsOhio, Invenergy is collaborating with Chinese solar equipment company LONGi on the project. The solar panel manufacturing plant in Ohio is located near Pataskala. This is about 20 miles east of Columbus in Licking County. Additionally, it will receive an investment of $600 million from Invenergy.
The plant’s anchor customer will also be Chicago-based Invenergy, which was voted ENR Midwest’s 2022 Owner of the Year. The company states they have constructed solar projects across the United States and abroad. Their portfolio includes 775 MW of solar energy in Ohio.
More on the solar panel manufacturing plant in Ohio
The Biden administration is also aiming to expand domestic manufacturing in the solar industry. The Inflation Reduction Act of last year provided tax credits for US solar equipment makers. Furthermore, it extended tax incentives for their use. According to the White House, the country is on track to reach a domestic solar production capacity of 22.5 GW in 2019 from 7.5 GW in 2021.
Furthermore, Invenergy’s executive vice president of global sourcing, Art Fletcher, stated in a statement that his company “recognizes the importance of having a strong domestic supply chain to meet the fast-growing demand for affordable solar power” as the leading developer and operator of solar projects in the U.S.
