The Question Nobody Asks Until It’s Too Late
What happens when a 15-year-old solar farm needs replacement panels? In this eye-opening episode of The Solar Coaster, Steve Feinberg of Blue Water Battery reveals a corner of the solar industry most people never think about—until they’re managing aging installations that suddenly need parts that no longer exist.
Steve’s journey from battery recycling to sourcing hard-to-find solar equipment exposes the reality behind solar’s long-term viability: keeping systems running is often more sustainable, economical, and practical than chasing the latest technology.
From Batteries to Solar: An Accidental Evolution
“We started our business recycling batteries and doing battery deals, and we kept getting asked for solar panels,” Steve explained. “And after about the fifteenth time, I said, Okay, I’m going to see what I can do.”
That curiosity led to a thriving business helping solar farm operators find the exact replacement parts they need—often from systems that have been out of production for years.
The Market Need
“People needed older panels to keep their systems going. And it went well. And then we did another. And now it’s a good part of our business.”
What Steve discovered was a massive gap in the market: solar installations built 15-20 years ago are hitting the point where components fail or degrade, but finding exact replacements is nearly impossible.
The Reality of Aging Solar Systems
Steve dropped a statistic that frames the entire challenge:
“Everybody eventually will need our service, regardless of the percentage, because the system age across people need to find equipment. So in part of I think a lot of people out there are wondering, you know, you, you, you’re right. Now maybe they want to they’re tipping their toe into commercial solar utility scale. And but they’re not thinking long term.”
The 15-20 Year Timeline
Solar panels don’t suddenly stop working after their warranty period, but they do degrade. And when one component fails on a large installation, you can’t just slap in any replacement panel—you need something that matches the voltage, current characteristics, and physical specifications of the existing system.
“They’re not thinking about what the impact could be down the line,” Steve noted. “And I think a lot of people might believe that they’re operating their own plan or provider should be providing these types of replacement products.”
The Myth vs. Reality of Solar Replacement
One of Steve’s most valuable insights was dispelling the myth that manufacturers or installers naturally provide replacement services.
The Manufacturing Reality
“What happens is, is manufacturers do a production run or they have a certain model and the, you know, their customers want them to have more power in their, in their panels because obviously it uses less space, they get more revenue and so forth. So that these forms are built. But but the technology has moved past the farms.”
Manufacturers constantly chase higher wattages and improved efficiency. Today’s 600-800 watt panels replace yesterday’s 400-watt models. But farms built with 400-watt panels can’t simply upgrade to 800-watt panels without massive system changes.
The 5-10 Year Search Window
“So they they struggle after after the, the farms are maybe anywhere from five to ten years old to find panels that will will fit. And that’s where we come in.”
This creates a brutal reality: just when systems should be hitting their profitable stride, finding replacement parts becomes a scavenger hunt.
The Auto Industry Analogy
Steve used a perfect analogy to explain the secondary market for solar panels:
“Think of the think of the auto industry when when you first have your have your car and it’s going good. and you need a fender because you got into a, you know, somebody’s fender bender or you whatever it is and you have to pay full price from it from the factory. Well, ten years goes by and you can get it from the auto scrap yard for twenty cents on the dollar.”
The 25-Year Timeline
“And twenty five years go by and there’s not that many of them left anymore because they’ve either been consumed or recycled in the metal. And you still need to keep these farms going because it’s very, very, very expensive to to replace the panels.”
Just like classic car parts become harder to find over time, solar panels from discontinued production runs become increasingly scarce—except farms can’t just stop producing electricity because parts are unavailable.
The True Cost of Full Replacement
Steve’s most compelling argument for his business model is economic reality:
“It’s very, very, very expensive to to replace the panels. And I guess what I’m saying is somebody eventually replaces the panels, and then somebody picks them up and they either remanufacture them or somebody has surplus equipment that, that they’re holding on to, you know, for maintenance on, on these things.”
The Full System Impact
“If you’re going to replace all the panels now, you have to do all the engineering. If it’s a solar farm, you have to pull up all the racking. You have to lay all new wires, get all new inverters, all transfer everything. And so it’s actually it’s actually easier to start from scratch than it is to pull everything, everything out and permitting, you know, all of those things.”
This is the hidden cost nobody discusses during sales presentations: retrofitting an existing solar farm with completely new technology often costs MORE than the original installation because you’re essentially building new while dealing with existing infrastructure.
The Environmental Case for Reuse
Beyond economics, Steve made a powerful environmental argument:
“And it’s a very, you know, I mean, environmentally, it’s a terrific business. Absolutely.”
Extending System Life
Rather than prematurely replacing functional systems, finding compatible replacement parts extends the productive life of solar installations—reducing waste, avoiding manufacturing emissions for new panels, and maximizing the environmental benefit of systems already deployed.
“And how do you find these products?” I asked.
“It’s relationship. I mean, I think even and I’m not doing what you do, but, you know, I’ve been through several bankruptcies with different providers and, and I’ll get calls from dealers like, oh, we have a warehouse full of panels and I know someone else who wants them because I work with so many solar companies.”
The Matchmaking Service
Steve describes his business as matchmaking—connecting farms that need specific equipment with sources of surplus or remanufactured panels.
The Network Effect
“I mean, this seems like matchmaking, right? It’s like a match, you know, almost like an app. Like a dating. Yeah. Right. Exactly. When when the right time comes, they think of you and they call you.”
This network took years to build but creates enormous value by solving a problem that would otherwise force premature system replacement.
The Bankruptcy Opportunity
“I’ve been through several bankruptcies with different providers and, and I’ll get calls from dealers like, oh, we have a warehouse full of panels and I know someone else who wants them.”
When solar companies fail, their inventory doesn’t disappear—it becomes surplus that Steve can redirect to farms that desperately need exactly those specifications.
The Tariff Impact
One of the biggest challenges Steve faces is navigating tariffs that dramatically affect panel availability and economics.
The China Factor
“Obviously, the tariffs are affecting things dramatically because, you know, all of a sudden, you know, if you can get panels for ten cents a watt in China, you and you can see that the tariffs make them much more interesting here or price competitive here.”
Domestic Surplus
“But, but, uh, transparently, um, product overseas sometimes is very easy from some countries and some countries is almost impossible. Um, and we’ve been on both sides of the fence. We’ve had batteries that we’ve brought in from Europe and, and we found homes for them. No problem.”
The tariff environment creates opportunities for domestic surplus panels that might otherwise be exported—making Steve’s matchmaking service even more valuable.
The International Complexity
Steve revealed surprising challenges with international equipment movements:
The Third World Challenge
“But we’ve we’ve had some third world countries that we’ve had some real I shouldn’t really call it Third World. That’s not correct. But we’ve had some countries that we’ve had some difficulty with and, you know, it’s you know, that’s that’s kind of part of your service.”
Working across borders requires understanding customs regulations, shipping logistics, and local business practices that can vary wildly.
The Art of Documentation
“That’s like an art form that you’re able kind of of what you’re able to do is really understand that and help them get the paperwork in place to be able to replace these products.”
Success in this business requires more than finding panels—it requires navigating complex international trade regulations.
The Fraud Problem
Perhaps most concerning, Steve revealed growing fraud in solar manufacturing:
“So let’s switch it a little bit for me. Uh, you know, one thing that we’re seeing in other industries is fraud, right? You know, and and I want to know, are you seeing that in your in your product array? Like, here you are. You’re looking for something very specific. Are there any companies out there fabricating this old inverter that is really that is really that’s a great question.”
The China Manufacturing Risk
“And the answer I would tell you is it exists, but it exists if you’re buying the product from China. But remember, most of our business is we’re getting our product in the US. It’s already been brought in. So, um, it’s been a few, you know, it’s been here for a few years. So likely if there was fraud, it would have been caught by now.”
The Copycat Concern
“But we haven’t—we haven’t seen very much of it. But I do know it exists. And I know there are people that, you know, they copy Trina solar panels, they copy JinkoSolar, and they, you know, they give them their serial numbers, and they ship them to the US.”
This fraud risk adds another layer of complexity to sourcing—and another reason why Steve’s established network and vetting process provide value.
The Technology Leapfrog Fallacy
One of Steve’s most counterintuitive insights was about why upgrading to newer, more efficient panels isn’t always the right answer:
“So it’s really a terrific service. And even though it’d be nice to have a higher wattage panel there, the reality is those sites were built at a time, and they’re producing the amount of electricity they were designed to produce, where they were going to be successful and profitable.”
The Production Design
Solar farms were engineered for specific production levels based on available technology at the time. They’re profitable at those levels. Upgrading might increase production, but at what cost?
“Um, so there’s no real need to update them now. Eventually the day will come when there’s no way to support it, and it makes more sense to pull it out. But by doing that, potentially you’ve leapfrogged the technology.”
The Leapfrog Advantage
“So instead of going from a four hundred watt panel to a six hundred watt panel, all of a sudden I hear in the future it’s going to be like the size of a roof? Nope. Different design. Eleven hundred watt. They’re just they just made it. I read about it.”
By keeping older systems running longer, operators can eventually skip multiple generations of incremental improvements and jump directly to transformational new technology when replacement finally makes economic sense.
Key Takeaways from Steve’s Replacement Market Insights
1. Every solar farm will eventually need replacement parts. It’s not if, but when.
2. Manufacturers don’t provide long-term part availability. They chase higher wattages and new models.
3. Full system replacement is extremely expensive. Often more than starting from scratch.
4. Reuse and remanufacturing are environmentally superior. Extending system life reduces waste.
5. Tariffs dramatically affect the replacement market. Creating both challenges and opportunities for domestic surplus.
6. International logistics are complex. Especially in developing nations.
7. Fraud exists in solar manufacturing. But established US supply chains mitigate risk.
8. Technology leapfrogging can be advantageous. Skip incremental improvements by waiting.
9. Relationship networks are everything. Matchmaking requires years of industry connections.
Why This Episode Matters
Steve Feinberg reveals a critical aspect of solar’s long-term sustainability that rarely gets discussed during installation: what happens 15-20 years down the road when components fail?
For solar farm operators and commercial installation owners, Steve’s insights provide a roadmap for thinking about long-term maintenance and the hidden costs (or savings) of different approaches to aging systems.
For the broader solar industry, Steve’s work represents circular economy principles in action—maximizing the useful life of equipment already deployed, reducing waste, and proving that sometimes the greenest solution isn’t the newest technology, but keeping what you have running longer.
And for anyone considering commercial or utility-scale solar, Steve’s perspective offers a crucial reminder: build relationships with companies that can support your system not just at installation but throughout its entire lifecycle.
Listen to the Full Episode
Ready to learn more about solar’s hidden replacement market? Listen to this episode of The Solar Coaster on your favorite podcast platform:
Connect with Steve Feinberg and Blue Water Battery
Learn more about solar equipment sourcing and replacement services:
- LinkedIn (Personal): Steve Feinberg
- LinkedIn (Company): Blue Water Battery
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About The Solar Coaster Podcast
The Solar Coaster is a podcast that takes you on the wild ride through the solar industry, told by the people who live it every day. Hosted by Anna Covert—author, digital marketing expert, and founder of Covert Communication—each episode features candid conversations with solar professionals sharing their journeys, challenges, and victories.
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