Download - brintons project report
Project report
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Submitted by
Piyush s gundecha
Iccs (2009-10)
s.y.b.b.a (Roll No. 51)
ACKNOWLEDGMENTS
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Every work done needs to be followed by a deep sense of gratitude to those who made
it through to success. I take this opportunity to thank all those who rendered their immense
help & guidance for the completion of this report.
Firstly, I would like to express my gratitude to Henry Daniel (Logistic Export) of
Brintons, for his kind help and support by providing me with the necessary insights and
information.
Secondly, I would like to express my sincere gratitude to my project guide Mr. Amol
Shinde for his valuable guidance & support given to me endlessly from time to time.
Finally, I would like to thank my friends for their cooperation and advice during the
task of preparing this report.
PIYUSH GUNDECHA
INDEX
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INTRODUCTION
The Brintons family have been making carpets in Kidderminster since 1783. Michael
Brinton, is the sixth generation of the family to be involved in the business, which since it
began has focused on superior quality. In 1970 Brintons opened their first factory
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SR.NO TOPIC PAGE NO.
1. Introduction 4
2. Industry Profile 5-8
3. Company Profile 9-10
4. Product Profile 11-12
5. Management Structure 13
6. Objective of the Project 14
7. Manufacturing & Operation Details 15-19
8. Suppliers & Customers 20
9. Findings & Observations 21-22
10. Suggestions 23
11. Bibliography 24
in Telford, Shropshire, to make spun yarns. It has four units located at United Kingdom,
China, India and Portugal respectively with competitors only in China and Belgium. In
India, Brintons established its factory in 2000 in Mulshi Taluka.
Brintons is proud to be the world’s leading designer and manufacturer of Axminster
carpet and is the floor covering partner of choice for many of the world’s largest commercial
carpet customers.
The UK-based company has a rich heritage and has been redefining standards in
carpet design leadership and broadloom carpet manufacturing quality for 225 years. Brintons
will fulfil any Axminster carpet project requirement, whether for a large airport terminal
building or a luxurious hotel – anywhere in the world.
INDUSTRY PROFILE
Carpet was the major attraction of many royal palaces and aristocrat families in the
early periods. Nowadays carpet plays a significant role in the interior decoration; the use of
carpets in the houses and business establishments are highly inevitable. In the ancient times
this industry was in its boom with many skilled artisans and weavers. Jute yarn and silk
threads are the important raw materials for the carpet industries. Recently synthetic yarns are
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also used for the production of mats and rugs. Availability of raw materials, skilled workers,
understanding of the traditional weaving patterns, accessibility of capitals, competition,
marketability etc are the major factors affecting the existence of this industry.
China, Afghanistan, Pakistan, India, Persian countries, France, US, England, Russia
are the major contributors to this industry. Millions of weavers are working day and night in
the carpets and mat industries in order to meet the demands of the mass.
Industrialization in late 30's introduced the concepts of mechanized patterns for
weaving the rugs and mats, which initiated the concept of mass production. The US carpet
industry started its mechanized operations in the year 1791 in Philadelphia and the first
broadloom carpet was introduced in the year 1877. Over the centuries Iranian hand woven
carpets gained much attraction in the world wide. The diversified designs, super quality and
brilliant hand work keep preserving the world wide demand for the Iranian carpets in the last
few decades. But the economic recession in the Europe, Japan and United States affects the
export of Iranian carpets from 2000 onwards.
By 2002, the export for these carpets was dropping down $600 million by compared
to the previous years. Carpets from India also have remarkable glory in the minds of carpet
lovers of domestic and international markets. Numbers of artisans are working in different
places of India like Rajasthan, Madhya Pradesh, Uttar Pradesh, Gujarat etc. In Pakistan carpet
manufacturing is mainly undertaking in the areas like Quetta, parts of NWFP, Karachi and
Attock. Pakistan is exporting carpets and rugs mainly to USA, Germany, Italy, the UK,
France, and UAE. Till 2000, the export from various countries to the international market
was stable.
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The worldwide economic recession affects the export of carpets; this affects the life of
the weavers also. Mechanization of this industry coarsely hit the daily lives of the artisan's
families, most of them left jobless and finds other jobs. Afghan refugees were the major
carpet weavers in Pakistan; the return of these refugees created a big decline in the
production of carpets. Lack of raw materials, lack of professional approach, competition
internally and externally, lack of coordination, shortage of working capitals etc. are other
factors declining the growth of this industry. Now the governments of various nations are
providing different platforms for recovering carpet industry from its slowdowns.
Types of Carpets: There are various kinds of carpets available in India. These are as follows
• Hand-knotted Woollen Carpets
• Tufted Woollen Carpets
• GABBE Woollen Carpets
• Handmade Woollen Dhurries
• Pure Silk Carpets
• Staple or Synthetic Carpets
• Chainstich Rugs
Market Size and Segmentation: The carpets manufactured in India are mainly
exported. There is a very small market for carpets in India. This is mainly because of the
purchasing power of local players. Also, there is no proper channel for marketing these
products in India leading to lack of awareness in the Indian market. Presently, India exports
carpets worth over Rs. 2600 crores. The domestic market size is about Rs.200 crores.
Following table shows comparison of exports from India
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Carpet industry’s major products are hand-knotted and hand tufted carpets.
Hand-tufted carpet market is growing rapidly. Following chart shows the product wise
market share in Indian exports.
SWOT Analysis Of Carpet Industry In India:
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STRENGHTS:
Artistic Skills
Lower costs
Innovations
Flexibility
WEAKNESSES:
Unorganized
Narrow Marketing Channels
Poor Infrastructure
Lack of Professional
Approach
Unhealthy Internal
COMPANY PROFILE
Brintons is proud to be the world’s leading designer and manufacturer of Axminster
carpet and is the floor covering partner of choice for many of the world’s largest commercial
carpet customers.
Axminster and broadloom carpet manufacturing: The UK-based company has a rich
heritage and has been redefining standards in carpet design leadership and broadloom carpet
manufacturing quality for 225 years. Brintons will fulfil any Axminster carpet project
requirement, whether for a large airport terminal building or a luxurious hotel – anywhere in
the world.
Brintons has a hand-picked team of 80 designers strategically positioned around the
world that, together with Brintons expert project managers, project designers and architects to
fully understand what the client requires. This approach allows Brintons to deliver valuable
carpets.
Custom-woven Axminster carpets : As the world’s largest producer of Axminster carpet,
Brintons understands how a custom woven carpet must be manufactured to ensure it meets its
performance targets. Brintons experience and manufacturing excellence ensures that its
broadloom carpets are easy to install, offer unrivalled resistance to shading and pile reversal
and are extremely hard wearing. The company pioneered the 80/20 blend of natural wool
yarn and nylon yarn that ensures all of its commercial carpet hides soil, has low flammability,
is easy to clean and has excellent colour and design retention while also offering excellent
resistance to abrasion. A Brintons Axminster carpet will maintain its luxurious appearance
and last longer than any other equivalent commercial carpet.
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STRENGHTS:
Artistic Skills
Lower costs
Innovations
Flexibility
WEAKNESSES:
Unorganized
Narrow Marketing Channels
Poor Infrastructure
Lack of Professional
Approach
Unhealthy Internal
Commercial carpets worldwide : Brintons works with commercial carpet clients all over the
world and members of its 2000-strong global workforce occupy design and sales offices in all
the key markets around the world including Singapore, Europe, the US and Australia.
Brintons has state-of-the-art manufacturing facilities in the UK, Portugal and India and will
shortly enhance its global customer reach even further by opening a brand-new production
facility in China.
Commercial sectors : Very few Axminster carpet suppliers can lay claim to having such a
diverse client base as Brintons. The company’s impressive reputation has been built on the
strong results it consistently achieves in airports – the 100,000m² installation of Axminster
carpet at Singapore’s Changi T3 being a case in point - the hospitality sector – Brintons is an
approved global supplier to the Marriott and Hilton hotel chains - conference centres, public
spaces, the marine industry, the leisure sector, and sports stadia. No project is too big or too
small for Brintons.
Quality of service : When Brintons starts work on a new project, it’s imperative that the
customer service it provides during the project matches the quality of the Axminster carpet
that is designed and eventually installed.
Brintons Promise to Customer: “All our carpets are made to consistent quality standards and
we are confident that you will be delighted with your purchase. In the unlikely event that you
have a complaint as a result of a manufacturing fault, we guarantee to rectify or replace the
carpet to ensure your total satisfaction.”
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PRODUCT PROFILE
Perceptions
The ‘Perceptions’ collection offers a snapshot of designs that are relevant to today’s interiors,
as well as giving a taste of trends that are just around the corner.
Reverb
'Reverb' illustrates different elements within today's environment and is divided into four
distinct chapters: organic, micro, urban and flight
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Hand Painted Sketches
Great design is timeless and the Brintons design archive houses a rich collection of design
inspiration in the ‘hand painted media’ that covers every culture and style imaginable.
Genesis
Start with fresh ideas for your next premier interior project with Genesis - an extraordinarily
diverse series of impressive contemporary Axminster carpet designs.
Some other carpet collection that the company offers are Dunbar-Cullum Anthology,
Katagami, Biedermeier, Art Fusion, etc.
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MANAGEMENT STRUCTURE
The structure of the management is shown in the diagram below:
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CHAIRMAN
BOARD OF DIRECTORS
DIRECTOR
MANAGING DIRECTOR
GENERAL MANAGER
PERSONNEL MANAGER
SUPERVISOR
WORKERS
FINANCE MANAGER
SUPERVISOR
WORKERS
RESEARCH & DEVELOPMEN
T
SUPERVISOR
WORKERS
MARKETING MANAGER
SUPERVISOR
WORKERS
SALES MANAGER
SUPERVISOR
WORKERS
OBJECTIVE OF THE PROJECT
The project is prepared to fulfil various objectives. The objective to prepare this project
is:
I. To understand the working of the carpet industry.
II. To understand how the company works in real sense.
III. To understand the manufacturing process of carpet industry.
IV. To realize the importance and the role played by the company in the economy.
V. To understand the importance of quality maintenance.
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MANUFACTURING PROCESS
1. Preparing the yarn
Synthetic yarns arrive at the carpet manufacturer either in staple fiber form or bulk
continuous filament form. The staple fibers, which average 7 inches long, are loose,
individual strands that arrive in bales. Several bales are blended together into one
batch in a hopper. Then, after lubrication, they are spun into long, loose ropes called
slivers by a carding machine. The slivers are then pulled, straightened, and spun into
single yarn that is wound onto spools.
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The yarns are then steamed to bulk them, and then heated to 270-280°F (132-138°C).
This heat setting causes the yarn to maintain its shape by fixing its twist. After
cooling, these yarns are wound onto tubes and transported to the tufting machines.
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2. Dyeing the yarn
Most carpets are dyed after tufting, yet sometimes the yarns are dyed first. The
methods include putting 500-1,000 pounds (227-455 kg) of fiber into pressurized vats
through which treated dyes are circulated, or passing the fiber continuously through
the bath, or passing skeins of yarn through the vat of dye. The yarn can also be put on
forms, and the heated dyes can then be forced under pressure from inside the forms to
color the yarn. Another method passes the yarn through printing rollers, while yet
another involves knitting the yarn onto a form that is then printed with dyes before the
yarn is unravelled. All yarn that has been dyed is then steamed, washed, and dried.
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3. Tufting the carpet
The yarn is put on a creel (a bar with skewers) behind the tufting machine, then fed
into a nylon tube that leads to the tufting needle. The needle pierces the primary
backing and pushes the yarn down into a loop. Photoelectric sensors control how
deeply the needles plunge into the backing, so the height of the loops can be
controlled. A looper, or flat hook, seizes and releases the loop of yarn while the
needle pulls back up; the backing is shifted forward and the needle once more pierces
the backing further on. To make cut pile, a looper facing the opposite direction is
fitted with a knife that acts like a pair of scissors, snipping the loop. This process is
carried out by several hundred needles (up to 1,200 across the 12 foot [3.7 ml width),
and several hundred rows of stitches are carried out per minute. One tufting machine
can thus produce several hundred square yards of carpet a day.
4. Dyeing the tufted carpet
Dyeing printed carpet is to pass it under embossed cylinders that have raised portions
in a design, which press color into the carpet. Each cylinder provides a different
design for a different color. After dyeing, the printed carpet is steamed, excess dyes
are washed off, and the carpet is then dried and put onto rolls to go to the finishing
department.
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5. Finishing the carpet
The ends of the dyed carpet are first sewn together to form a continuous belt. This belt
is then rolled under a dispenser that spreads a coating of latex onto the bottom of the
carpet. At the same time, a strong secondary backing is also coated with latex. Both of
these are then rolled onto a marriage roller, which forms them into a sandwich and
seals them together. The carpet is then placed in an oven to cure the latex.
The completed carpet is then steamed, brushed, vacuumed, and run through a
machine that clips off any tufts that rise above its uniform surface. The carpet is then
rolled into 120 foot (37 m) lengths that are then packaged in strong plastic and
shipped to either the carpet manufacturer's inventory warehouse or to a retail carpet
store.
6. Quality Control:
Every piece of carpet that is tufted is inspected to see if any tufts are missing. One
person with a single needle tufting gun shoots pile yarn wherever holes are found.
Each piece of carpet is then inspected. The manufacturer checks that the piece is of
the proper dimensions and that the tuft height is of the desired length.
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SUPPLIERS, CUSTOMERS & COMPETITORS
SUPPLIERS:
The raw material is imported from New Zealand & Australia.
UK & US famers.
Dye is imported from Germany & UK.
CUSTOMERS:
White Housen
Indira Gandhi International Airport, India
Taj Hotel, India
Oberoi Hotel, India
Le Meriden, India
Hyatt Hotel, India
MGM Grand Casino in Las Vegas
Majesty's Theatre in Aberdeen
Hong Kong Airport
COMPETITORS: Major competitors are in China & Belgium
JABP Join Long Carpet Co. Ltd, China
Zhejiang Xingyue Carpet Industry Co. Ltd , China
Balta Group, Belgium
Lano Carpets, Belgium
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OBSERVATIONS & FINDINGS
During our visit Brintons Carpets Asia Pvt. Ltd. and while preparing this report, I
observed various things. They are:
1. Established in 1783 in UK.
2. It owns and operates other factories all over the world including
Australia, Portugal, and India
3. Raw material is imported from New Zealand & Australia & sent to UK & it is
reprocessed in UK & proper distribution is made to their various factories. In short,
they have Inventory Department in UK & they keep their inventories only for 3
months.
4. They have setup their factory in India because of cheap labour & certain government
relaxations.
5. They have competitors only in China & Belgium.
6. Their turnover in India is around 100 crores.
7. They have capacity of 25,000 carpets per week & they give warranty for 3-5 years.
8. Their major customers in India are Taj, Oberoi, Le Meriden, Blue Diamond, Holiday
Inn, Hyatt Hotel, etc.
9. They have supplied carpet to Delhi Airport, around 1, 73,000 sq.ft.
10. They have total 6 storages which has a capacity of 10 tonnes.
11. There are 600 employees & total 3 shifts, working 24X7.
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12. They have 2 lacs litre requirement of water per day.
13. They take minimum order of carpet for 500 sq. ft.
14. Dye is imported from Germany & UK.
15. Machines are made by Thermax Company.
16. The Brintons product portfolio includes premium woven Axminster and Wilton
broadloom carpets, tiles and handcrafted rugs.
17. Brintons is a market-leading supplier of carpets to the worldwide hospitality, marine,
gaming, leisure, private and public sectors.
18. Brintons is committed to the concept of thinking global and acting locally. It has
design studios, offices and agents in all of the major markets around the world.
19. Brintons carpets are long life products. Unlike inferior, all synthetic carpets, they are
not replaced on a frequent basis & therefore do not contribute to excessive land fill &
other waste problems.
20. Brintons carpets are woven using 80% pure new virgin wool & 20% premium nylon.
Wool is one of the most environmentally responsible fibres, being the ultimate
renewable resource.
21. As an ISO 14001 accredited company.
22. Brintons have also initiated special agreements with our Suppliers to ensure that all
containers and other materials brought onto the company are either returned to the
Manufacturer to be re-cycled, or are disposed of by safe, secure and legal methods.
23. Unit requirement of raw materials is 50 tonnes per week.
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SUGGESTIONS
After the visit and while preparing this report I think there are certain things that the
company should take care of.
1. Adequate space should be created to move around for workers working near
machineries.
2. Adequate lightning is needed.
3. Spittoons should be installed near dyeing area as chemical process is involved.
4. Machines should be properly cleaned & maintained.
5. They can try to adopt a strategy of gaining other markets around the world by
reducing their prices.
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BIBLIOGRAPHY
I took certain references and various help while preparing the project. The internet was
the main source from where we found the information. The list of URLs used for the
reference is listed below:
1. http://www.dessenceconsulting.com/pdf/Carpet.pdf
2. www.google.com
3. www.brintons.net
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