A Walk in the Factory

December 13, 2022

The demand for Modular kitchens has been increasing in the kitchen industry as they are developed to put an end to all types of kitchen design issues. Eventually, new homeowners go for setting up modular kitchens since they want their kitchens to be eye-appealing all year round. In order to get a first-hand experience of what goes into making the modular kitchen durable, appealing and functional, Kitchen Ideas team visited a factory in Pune to find out more.

Kitchen Grace claims to be the first modular kitchen company in India. Established in 1988 with a modest beginning, today, it is the only Indian company which has over 16-year-old installed modular kitchens that are fully functional today in residences across the country.

A combination of veneer and wood is shown to give a rich look. The oak veneer is stained with walnut shade. There are other options like wenge, teak and black. Photo Courtesy: Kitchen Grace

Company

At the factory

Though the factory is located in the exteriors of Pune city, the locality seems to be very calm and peaceful. The interiors are kept simple yet cluttered free and the huge equipment or the machines are placed in a manner that facilitates work efficiency. Major manufacturing work is carried out in the ground level which includes the initial stages of manufacturing like cutting, drilling, finishing, polishing, etc.

Built on the outskirts of the city, the 40,000 sq. ft. factory is almost always bustling with activity that involves European woodworking machines and an automatic through feed Polyurethane painting line.

Backed by a well-developed infrastructural facility, which is equipped with requisite machines and technologies, the group is capable of manufacturing the product ranges in bulk quantities at a rapid pace. Further, this unit is segregated into various departments to carry out all the operations in an efficient and timely manner. The company is known to manufacture approximately over than 3,500 kitchens a year.

Snehal Vasani, Managing Director, Kitchen Grace said, “We believe that comfort cannot be achieved without giving due importance to ergonomics, the right design and the correct manufacturing process. The importance of designing lies in creating a space where everything fits in seamlessly, which in turn results in high efficiency and prevents unnecessary wastage of energy.”

He mentioned that every kitchen that they make gets full attention in terms of functional and ergonomic detailing by keeping customers' needs on priority. “There is a very thin line between the customer’s needs and desires. We excelled at understanding this difference over the period of time, and still continue to follow that,” he commented.

A number of features and specialities make different varieties of kitchen modules stand out from each other. Photo Courtesy: Kitchen Grace

Designation

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Design features

There are a number of salient and vital factors that account for the quality of the finished product. To keep a check on the pollution and the air quality control inside the premises, especially in the work area, level air handling units are installed inside the factory which supply filtered humidified and pressurised air in a closed chamber. Also, dust collectors have been installed for each machine to get a completely dust-free environment.

An expert team of personnel caters to the demands of clients as per their specific requirements to ensure impeccable quality, especially since the factory produces products that have to match international specifications. With a wide distribution network and logistics setup, the group claims to have successfully achieved a strong client base across the continent. In May 2011, the company exported 86 kitchens project for VIVA, (a commercial real estate venture in Tanzania.) which included 2BHK, 3BHK, 4BHK apartments and a penthouse in Dar es Salaam, Tanzania. Also, in October 2011 they exported 20 kitchens to Saival Enterprises Pvt. Ltd. in Nairobi.

The factory tour revealed the complete range of finishes such as veneer shutters, laminated shutters, glass shutters and PU-painted shutters in MDF and Marine ply (BWR) substrate that is used for the products.

Each module is based on different storage requirements and needs, following which according to the requirements the design is planned and the production is carried out.

Once the design plan is finalised, it is converted into a 2D/3D drawing, for every wall and every view which helps in detailed understanding and to avoid errors. Every process goes under automation including a hydraulic press for pressing the laminates on wood or ply, and sealing the edge with PVC/ABS edge banding for a better finish, a CNC (Computer Numerical Control) machine is used for high precision in drilling holes for distance and alignment purpose. Also, a cutter for metal frames, two-way tape for glass fixing, and punching for easy grounding make the process more efficient and time-saving. For a soft close experience, Blum technology is used in drawers and shutters. The countertop is installed with silicon to get a flexible watertight joint. whereas the PVC plinth can be removable for cleaning purposes.

Design features

Each module is based on different storage requirements and needs, following which according to the requirements the design is planned and the production is carried out.

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Designation