For more than three decades, EXUS AI Labs has been at the forefront of European research and innovation. With a mission to design robust, trustworthy and human-centred AI solutions, the team brings together seasoned research engineers and consultants who specialise in harnessing the power of big data across sectors as diverse as energy, smart cities, infrastructure, health and education. Their work is all about unlocking the hidden value in complex datasets and translating it into tools that deliver real-world impact.
Today, EXUS is proud to serve as a key technology partner in CIRCMAN5.0, the Horizon Europe project redefining the future of circular photovoltaic (PV) manufacturing. And their contribution is nothing short of pivotal.
Forecasting the Environmental Impact of PV Manufacturing
One of EXUS’s major roles within CIRCMAN5.0 is the development of advanced AI models capable of forecasting the environmental footprint of PV systems across their entire lifecycle, from manufacturing and logistics to operation and end-of-life processing.
These models make it possible to compare alternative materials, designs and production configurations, helping manufacturers minimise energy consumption and reduce environmental impacts. All insights flow directly into the project’s Life Cycle Assessment (LCA) and Digital Product Passport (DPP) workflows, ensuring that sustainability sits at the core of every technical decision.
Human-in-the-Loop Recommendations for Circular End-of-Life Pathways
EXUS is also pushing circularity a step further through the development of a human-in-the-loop recommendation engine. This intelligent tool supports decision-making around the most sustainable end-of-life strategies for PV systems, covering a full spectrum of circular economy “R-strategies”:
- Repair options that extend product lifetime
- Remanufacturing using viable existing components
- Recycling pathways that maximise material recovery
The engine provides transparent cost assessments for each option, guiding manufacturers towards the optimal route based on system type, condition and economic parameters.
Making Sense of Energy Data from the Factory Floor
Beyond lifecycle modelling, EXUS also analyses the rich data collected by sensors installed across solar panel manufacturing equipment. Their goal is to map the baseline behaviour of each machine, during start-up, steady-state production, shutdown and even overnight downtime.
By detecting anomalies such as power factor deterioration, harmonic distortion or phase imbalances, EXUS helps plant managers identify early signs of equipment degradation and intervene before problems escalate.
By bringing clarity to complex industrial data, EXUS AI Labs equips manufacturers with the insights they need to make smarter, greener and more circular decisions across the PV value chain.