Project report

On

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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