PV frames are critical structural components for module encapsulation. Their price is typically composed of two parts: the “aluminum ingot price” and the “processing fee,” with raw aluminum ingots accounting for as much as 70% to 80% of the total cost.
Industry estimates indicate that processing fees generally range from 2.1 to 2.4 yuan per meter, though leading large-scale enterprises can keep this figure below 2 yuan. Calculating the processing fee requires breaking down four key components: extrusion, tooling (molds), surface treatment, and batch cost allocation.
I.
Basic Formula: Aluminum Ingot Price + Processing Fee
- PV frame profile price = Aluminum ingot price + Processing fee (calculated per ton).
Based on an aluminum ingot price of approximately 22,000 yuan/ton and a processing fee of about 6,000 yuan/ton, the price is roughly 28,000 yuan/ton for natural anodized frames and 30,000 yuan/ton for black anodized frames (Source: Public data from industry manufacturers). - To determine the price of a complete PV frame set (two long sides + two short sides + four corner connectors), one must first calculate the total weight of the set, then multiply the weight by the material cost and add the machining fees.
- Raw aluminum ingots account for 78% to 80% of the cost structure, making them the core variable influencing frame prices (Source: PV aluminum frame industry report).
- Processing fees account for approximately 15%, environmental treatment for about 6%, and other management costs for around 1%;
fluctuations in aluminum prices significantly impact gross profit margins. - Custom frames also require the calculation of tooling costs;
the price of combined punching dies is high, necessitating a certain order volume to amortize the expense.
II. Aluminum Price: The Key Variable—Tracking LME and Spot Market Fluctuations
- LME aluminum prices are projected to climb from approximately $2,000–$2,200/tonne in January 2025 to $3,300–$3,500/tonne by May 2026;
raw materials account for over 70% of extrusion costs (Source: Fortune Aluminum Market Analysis). - In 2024, the average price of Changjiang Nonferrous A00 aluminum was approximately 19,850 RMB/tonne (up 3.2% year-on-year), directly driving a ~5.1% increase in the unit cost of frames (Source: PV Aluminum Frame Industry Report).
- For the EU market, LME aluminum prices are forecast to average €2,100–€2,600/tonne between 2025 and 2026, plus a Carbon Border Adjustment Mechanism (CBAM) surcharge of €50–€120/tonne (Source: IndexBox EU Market Analysis).
- Aluminum price volatility can cause frame costs to fluctuate by 10%–15% within a single quarter, necessitating monthly rolling updates to procurement budgets.
- Industry players commonly lock in raw material prices through long-term contracts;
leading companies use this strategy to maintain an average gross margin of around 12%, with top-tier firms achieving 18%–22%.
III.
Extrusion and Tooling: Core Components of Processing Fees
- Extrusion and processing premiums typically range from $0.50 to $2.00 per kilogram above the LME base price, depending on profile complexity, wall thickness, and alloy grade (Source: Aluminum Extrusion Procurement Guide).
- In the EU market, extrusion and processing fees range from €800 to €1,400 per tonne;
custom profiles for irregular shapes and dual-glass modules command higher fees due to stricter tolerances and complex mold-making requirements (Source: IndexBox EU Market Analysis). - Custom mold costs range from approximately $400 to $2,000 per set: $300–$800 for solid profiles, $800–$1,500 for semi-hollow profiles, $1,000–$3,000 for hollow profiles, and over $5,000 for multi-cavity structures (Source: Aluminum extrusion cost estimation data).
- Mold lifespan typically ranges from 50,000 to 300,000 meters;
when amortized across order volumes, the per-unit mold cost decreases rapidly as production output rises. - Processing fees are influenced by energy prices and labor costs: the processing fee per ton increased from RMB 3,200 in 2023 to RMB 3,450 in 2024. Energy consumption shares for the various stages—melting/casting, extrusion, aging, and surface treatment—are approximately 35%–50%, 20%–30%, 5%–10%, and 15%–20%, respectively (Source: Industry cost analysis).
IV.
Surface Treatment: Significant Price Difference Between Natural Anodizing and Black Coloring
- Anodizing is the standard surface treatment for PV frames;
silver frames utilize natural anodizing, while black frames undergo an additional coloring step prior to the sealing process, resulting in a higher price for black frames compared to silver ones (Source: Public data from industry manufacturers). - Standard anodizing adds approximately €150–€300 per ton (EU standard) or roughly $0.12–$0.18 per meter (Source: IndexBox and industry pricing data).
- Anti-PID (Potential Induced Degradation) coatings add approximately €400–€700 per ton and are primarily intended for large-scale ground-mounted power plants operating in high-voltage, high-humidity environments.
- Driven by rising green manufacturing requirements, the adoption rate of eco-friendly surface treatment processes—such as anodizing and fluorocarbon spraying—rose from 58% in 2023 to 65% in 2024, with environmental protection investments accounting for approximately 6.3% of total operating costs (Source: PV aluminum frame industry report).
- Demand for frames for bifacial (dual-glass) and non-standard modules is growing rapidly;
the annual growth rate for this category within the EU market is projected to reach 14%–18% between 2026 and 2030 (Source: IndexBox EU market analysis).
V. Module Size and Alloy Upgrades: Increases in Both Material Usage and Strength
- Mainstream module sizes have transitioned from 166mm to 182mm and 210mm;
the amount of aluminum framing required per megawatt of modules rose from approximately 0.7 tonnes in 2020 to about 0.95 tonnes in 2024 (Source: PV aluminum frame industry report). - As module power output increases and load-bearing requirements become more stringent, frame materials are shifting from the commonly used 6063 alloy to the higher-strength 6005 alloy, leading to a corresponding rise in raw material costs.
- PV frames operate in harsh environments, requiring greater anodic oxide film thickness and superior corrosion resistance compared to standard aluminum frames;
their cost structure differs significantly from that of aluminum profiles used for doors and windows. - Lightweight, high-strength alloys and thin-walled designs are emerging trends;
the weight of a single module frame in the Canadian market is projected to decrease from 2.5–3.0 kg in 2026 to 2.0–2.5 kg by 2035. - High-strength alloys (6005A-T6, 6061-T6) and frames compatible with bifacial modules command a price premium of 10%–25% (Source: IndexBox Canada market analysis).
VI.
Market Benchmark Prices: From Ex-factory to CIF
- The average ex-factory price for standard Chinese PV aluminum frames (6063-T5) was approximately 23,800 RMB/tonne in 2024, with a projected fluctuation around 24,200 RMB/tonne in 2025 (Source: PV aluminum frame industry report).
- For the EU market, the landed cost of standard anodized frames is approximately €3,200–€4,500 per tonne, while frames with Anti-PID coating range from €3,800 to €5,200 per tonne (Source: IndexBox EU market analysis).
- In the North American market, standard anodized frames for 182mm 72-cell modules (weighing approx. 2.5kg) cost roughly CAD 4.50–6.50 per unit, while Anti-PID coated frames range from CAD 5.50 to 8.00 per unit (Source: IndexBox Canada market analysis).
- Prices for PV frame aluminum profiles in international wholesale channels generally fall within the USD 1.8–3.9 per kilogram range, fluctuating based on alloy type, surface treatment, and order volume (Source: Alibaba platform quotes).
- Industry benchmark: Frames account for approximately 8%–12% of the total cost of PV modules;
standard anodized frames cost roughly USD 0.35–0.55 per watt (Source: Industry procurement data).
VII. Volume and Procurement Strategies: Clear Leverage of Volume on Price
- Framework agreements involving annual procurement volumes exceeding 5,000 tonnes in the EU market can secure discounts of 5%–15%;
OEM agreements for over 50,000 frames annually offer similar 5%–15% price reductions (Source: IndexBox market analysis). - In international procurement, orders exceeding 100 tonnes typically allow for price reductions of 7%–12% (Source: Industry procurement guidelines).
- It is recommended to pay for mold costs upfront and stipulate mold ownership in the contract to avoid being locked into a single supplier through cost amortization in the unit price.
- LME price-linked clauses and quarterly price adjustment mechanisms are key tools for managing aluminum price risks;
fixed-price contracts carry a high risk of loss during periods of rapid aluminum price surges. - Yongzhen Technology, a leading domestic manufacturer, shipped over 800,000 tons of aluminum frames in 2024, capturing a market share of approximately 18%;
as market concentration among top players increases, bargaining power varies, making it advisable to compare multiple quotes before signing long-term agreements.
Procurement Recommendations
- Break down quotes into five cost components—aluminum ingot price, extrusion processing, surface treatment, mold cost allocation, and logistics—and compare them item by item rather than focusing solely on the total price.
- Incorporate LME aluminum price linkage clauses into contracts with monthly or quarterly price adjustments to mitigate the risk of 10%–15% quarterly fluctuations in aluminum prices.
- During the transition to larger module sizes, evaluate the use of 6005 high-strength alloy and lightweight designs to strike a balance between load-bearing requirements and costs.
- For large-volume orders, prioritize covering mold costs and locking in annual discounts;
for small-volume orders, inquire about standard profiles first to avoid mold-opening expenses. - For export projects, pay close attention to CBAM surcharges and tariff policies, and use the landed price (CIF/DDP) rather than the ex-works price as the benchmark for price comparisons.
