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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
Avenir Light is a clean and stylish font favored by designers. It's easy on the eyes and a great go to font for titles, paragraphs & more. Avenir Light is a clean and stylish font favored by designers. It's easy on the eyes and a great go to font for titles, paragraphs & more.
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
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.
Avenir Light is a clean and stylish font favored by designers. It's easy on the eyes and a great go to font for titles, paragraphs & more. Avenir Light is a clean and stylish font favored by designers. It's easy on the eyes and a great go to font for titles, paragraphs & more.
Full Name
Designation
THE FLOW CHART
Pressing the laminate/veneer: Hot press:
A hot press machine is used to avoid any bubble generation.
Cutting:
A beam saw is used for cutting the sheets to achieve precision. Also, a CNC is used for cutting.
Edge banding:
The raw edges of the panels are seamlessly edge banded after pre-milling operations followed by corner-edge radius and buffing. Pre-milling is done to avoid chipping and for better edge finishing.
Drilling:
The bottom and sides of the carcass then get drilled on multi-boring. It ensures precise and standard drilling patterns each time. For drilling drawers or any other hardware, a CNC machine is preferred.
Edge sanding:
An automatic edge sanding machine equipped with all necessary units is used to give quality output. This machine provides fine sanding of radius, corner and edges. Fine sanding helps in better adhesion of Polyester (Primer).
Top sanding:
The top surface gets sanded completely in the machine which helps in paint adhesion. Different grits of sandpaper are used to achieve fine finishing. The top sanding helps in better polyester adhesion.
Painting and drying in the oven:
PU high gloss paint is sprayed with the help of 4 reciprocating guns and subsequently, panels move on a conveyor for uniform coating. Robotic hand spreads paint evenly on all the shutters in order to achieve a better finish.
Automatic Vertical oven:
This is used for drying panels in which filtered humidified and pressurised air is blown. Automatic loading and unloading are carried and the shutter moves into a vertical oven which is a closed chamber to prevent dust particles.
The final stage is assembling, which is done inside the factory before it gets dispatched. A quality check is done at the end of each process right from selecting the raw material to getting it packed for dispatch.
Video Description
Varied kitchen module designs
A number of features and specialities make different varieties of kitchen modules stand out from each other. The factory floor is compartmentalised into different sections on different floors. There are clearly demarcated zones for various activities of the manufacturing process. Floor workers, some of them working since the company started its operations, seemed engrossed with their work and were unmindful of the journalists observing from a polite distance.
The marketing teams across India send requirements for custom-designed ranges and a strict system works to manufacture them is followed. The entire flow chart is rigorously monitored.
There seemed to be an array of different materials and styles on the work floor. Some of them are-
Polyurethane painted kitchen
This range is offered in 22 mm thick with solid wood recessed handles and 17 standard colours and a complete RAL (RAL is a colour matching system used all over the world) range of colours on request. These are also customised to high gloss and matt finish.
Veneer kitchen
A combination of veneer and wood is shown to give a rich look. The oak veneer is stained with a walnut shade. There are other options like wenge, teak and black.
Glass kitchen
PU (Polyurethane) back-painted glass shutters having gola profile (extrusion of aluminium which acts as a handle & is recessed) enhance both the functional and aesthetic appeal. This is also available in 17 standard colours and RAL range of colours on special request.
Laminate kitchen
Red and dark colour laminated shutters give a contrasting look. Wall-hanging cabinets are designed in such a way as to break the monotony of parallel or straight kitchens.
The factory reflects the new initiatives that involve strong research on Indian consumers' mindsets, expectations and trends for their dream kitchen. Vasani stated, “We have our own standardisations and we like to follow those. For the custom design though we generate the detailed drawing first and then we add it into our library for future projects.”
[The article was published in the January-March 2015 issue of Kitchen Ideas magazine.]
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