The Urethane Blog
June 18, 2025
Industry sheds facilities, 1,600+ factory jobs in year of soft demand
Sheila Long O’Mara //Executive Editor, Furniture Today//June 17, 2025
HIGH POINT – A wave of factory shutdowns across the furniture, mattress and textiles sector is signaling sustained pressure on the industry as companies contend with soft demand, overcapacity and ongoing efforts to streamline operations.
Since June 2024, the industry has seen at least a dozen players either shutter facilities or announce plans to do so this year. More than 1,600 employees have been impacted as companies wind down targeted facilities.
Reviewing publicly available notices under the federal Worker Adjustment and Retraining Notifications (WARN) filed over the past 12 months reveals a tumultuous time across the home furnishings and mattress category.
While most of the closures are related to the mattress category, the furniture and textiles sides of the business haven’t been spared. The list reads like a who’s who in the industry with Serta Simmons Bedding, Corsicana Mattress Co., Resident Home, A. Lava & Son, and Hooker Furniture having all closed, or announced plans to close, facilities.
These moves follow a similar pattern seen in 2024 when Purple Innovation, Leggett & Platt and Culp Inc. all took steps to consolidate or scale back production footprints, citing ongoing, persistent macroeconomic challenges and shifting consumer behavior.
Leggett & Platt announced a massive restructuring in early 2024 with plans to close up to 20 facilities, while Culp set into motion its plans to close its Canadian operation in Quebec and consolidate two factories in Haiti. Purple’s restructuring consolidated three factories into its 850,000-square-foot McDonough, Ga., location late last year impacting 328 employees in Utah.
The supply side closures are unfolding in parallel with consolidation on the retail front. Regional and national home furnishings retailers have seen a flurry of bankruptcies, closings and acquisitions over the past several years, further pressuring suppliers to adjust production capacity.
Executives point to prolonged post-pandemic normalization, consumer confidence and inflation as catalysts for retrenchment. While some closures are part of broader restructuring efforts, others reflect deeper contractions in specific product categories, particularly mattresses, which have faced declining unit sales.
According to the latest data from the International Sleep Products Assn., total mattress market shipments of U.S produced and imported goods in 2024 dropped 8.8% year-over-year to 24.9 million units compared to 27.3 million units in 2023.
The first six months of 2025 have been active with announcements and closings.
As part of a realignment of its facilities, Corsicana closed its Shelbyville, Tenn., factory last week. According to a WARN notice filed with the state of Tennessee, the company indicated 47 employees would be impacted.
Serta Simmons Bedding is set to close its 533,000-square-foot Moreno Valley, Calif., factory this summer making it the seventh factory the company has closed since 2022. According to a WARN filing, wind-down operations will begin July 5 and run through Sept. 30, impacting 180 employees. The company said the move is part of its strategy to improve efficiency across its manufacturing footprint.
Ashley Furniture closed the 300,000-square-foot Resident Home factory in Jeffersonville, Ind., laying off 106 workers a year after the home furnishings brand acquired the mattress brand. Ashley officials at the time said the production would be consolidated into other Ashley factories.
In its consolidation strategy, Hooker Furniture said in March that it would close its warehouse outside of Savannah, Ga. The closure is set for this month, and the company has opened a warehouse in Vietnam designed to help reduce lead times. The Georgia facility opened in 2021 as an 800,000-square-foot operation to house the former Accentrics Home line, which closed in 2023.
Greensboro, N.C.-based Unifi, a global textile manufacturer, announced in February plans to close its Madison, N.C., factory this month. Another fiber and yarn spinner announced is closing its facility in Kings Mountain, N.C., at the end of the year. The layoffs at Patrick Yarn Mill, a maker of flame-retardant yarns acquired in 2017 by U.K.-based industrial thread manufacturer Coats, started last month and will continue through Dec. 31, according to a WARN notice with the state.
In April, fabric supplier Richloom Fabrics Corp. closed its High Point-based Richloom Weaving, citing home furnishings retail bankruptcies such as Big Lots, Badcock Furniture and Joann Stores. Fifty-four employees were affected by the closure. In Plant City, Fla., Leggett & Platt closed its facility this spring, impacting 78 employees as part of its overall restructuring announced last year.
A Lava & Son, a former textiles and cover supplier to the mattress segment, went out of business in the fall of 2024 shuttering its Chicago facility and putting 188 out of jobs, according to a WARN notice filed with the state of Illinois.
High-end furniture manufacturer EJ Victor shuttered operations in September 2024 citing damage from Hurricane Helene. The company said its insurance provider declined coverage for the factory damage and inventory loss leaving it with no choice but to close and lay off 122 employees.
www.furnituretoday.com/industry-issue/mattress-furniture-factory-closures-2025/
June 17, 2025
Do you remember Lanesborough’s ‘Flintstone House’? Here’s how it got its odd shape
- By Jim Shulman
I have always been fascinated with unusual houses, and over the years have visited many.
In the 1990s I was told by a friend that there was a house in Lanesborough on National Street made of foam. On a visit to the Berkshires, I had to find it and at least take photos.
My first thought when I drove up was that it looked like a cross between a couple of igloos and a large outgrowth of mushrooms. This then-vacant and boarded-up structure was built in the 1970s and described in a Berkshire Eagle article as something out of a Flintstones cartoon. From then on it apparently became known by local baby boomers as the “Flintstone House.”
This abode was the brainchild of the Raymond “Randy” Barriere of Lanesborough, who built it and lived in it when completed. Randy was the oldest of six children of Ernest R. and Jean Barriere.
Ernest was a 1937 graduate of Pittsfield High School who later earned an engineering degree at MIT. After college and the service, he took a job with the General Electric Co. in Schenectady, where he worked for 40 years before retiring in 1990.
Although the Barriere couple raised their children in Scotia, N.Y., they had family in Pittsfield and summered in Lanesborough for years at the family cottage at 44 National St.
Their son, Randy, graduated high school in 1961 in Scotia and then went to college at the University of Florida, where he majored in landscape architecture. While there he learned about out-of-the-box houses — specifically built with urethane foam. Randy left college in his senior year to pursue the construction of such houses and even built a small school using urethane foam.
After four years in the Air Force as a flyer, Randy and his new bride moved to the family cottage in Lanesborough. He decided to build his own house across from the cottage on family-owned land at 45 National St. His goal was to introduce to the Berkshire community its first foam homes. He planned to build a prototype and eventually give it to his parents as a future retirement gift. In 1973 at age 30, he completed the home and started his own construction firm in Pittsfield called Plexi-Foam Corp.
The foam technology was an interesting one, especially to both doubting and curious traditional builders in the Berkshires. Initially Randy had a concrete slab poured and included space for 4-foot foam footers. Basically, the structure was built around several large inflated balloons that were then sprayed with the urethane foam.
Randy’s, sister, Wendy Darling, shared with me that she and her mom, Jean, sewed the canvas to create the balloons and later helped install a chicken wire covering. The urethane was supplied in 55-gallon drums.
It had to be heated to 140 degrees and then it was sprayed from an airless gun. The urethane was not considered toxic as were many similar insulation chemicals that were banned in later years.
With his architectural background, Randy created a well-thought-out design and plan. A first floor or basement had burlap paneled walls squaring off the lower parts of the domed tops, which were also covered with the foam. Wooden decking to support the upper floor had been incorporated in the design.
After the foam settled, Randy had cut out space for doors and windows. He installed traditional doors and plexiglass oval-shaped, fixed windows primarily to let light in. He then added more foam to the outside to reach at least 4 inches of thickness and to seal tightly around the windows. Air circulation was accomplished by fans and venting, not through windows.
Finally, the entire outside structure was coated with off-white colored Duratite. This vinyl concrete sealant was for waterproofing the outside.
Randy’s younger brother, Greg, a Pittsfield architect, shared with me that a sealant also was applied on the inside, not only for waterproofing, but also to totally enclose the flammable urethane foam rendering the building fire safe.
The home was all electric, with wiring and minor duct work both enclosed in fiberglass. Greg said the building was so well insulated that a single light bulb could easily heat a whole room in the winter. In the summer the interior remained cool.
When totally completed, the building would be protected from drafts, fire, water leakage, and invasion of termites and other varmints. Randy claimed the structure would be maintenance-free for two to three decades and energy economical in all seasons due to the insulation offered by the foam.
The home’s design provided 1,600 square feet of indoor space in the two main domed sections. The downstairs or basement included a two-car garage, storage space and a workshop/utility room.
Between the two sections from the front door and passageway, Randy designed a curved stairway leading to the second floor with a laundry room a few steps up on a landing. Upstairs, the larger section had a living room, a dining room and a kitchen with a few steps down to a sitting area and fireplace. The other second floor section had a bedroom, bathroom and study.
From this prototype, Randy estimated his homes could be built for a cost of about $22 per square foot, or between $30,000 to $35,000 per home, with 1,300 to 3,000 square feet. The market was a tough one as new homeowners were unfamiliar with such an unusual construction.
Randy did build a larger structure in Connecticut, but most of his business was from projects such as insulating existing structures and adding foam rooms to traditional homes. He also served as a lecturer locally in programs on his unique constructions and on energy efficiency.
Randy Barriere was a pioneer in not only building unique foam houses, but he was one of the earliest contractors in the Berkshires to use foam insulation for more traditionally built homes. Unfortunately, his contracting business was a short-lived one. This innovative designer and contractor died in an auto accident on upper North Street near Crane Avenue on March 11, 1981. He was only 38 years old.
Randy’s wife continued living in the house for several years. In December 1985 a strong wind broke a hemlock tree at its trunk and it demolished part of the home. The damage was repaired, but soon afterward, his widow vacated the house, moving to Rhode Island to be close to her family.
When I visited the house in the late 1990s, some of the wood supports were exposed and the deck wood was rotting. A decade or so of neglect had taken its toll on the structure. Being boarded up, and covered with no-trespassing signs, I could not see the inside condition.
On Oct. 31, 2013, an explosion occurred at Flintstone House, causing the entire structure to burn to the ground. The cause of the blast was a mystery. With the destruction of the building’s sealants, the flammable urethane foam was exposed to the flames.
Debris was strewn over a quarter-mile radius surrounding the residence and smoke could be seen by motorists on Route 7 all along Pontoosuc Lake.
From time-to-time I read comments on local social media sites about the Flintstone House. It really was unique. I often think about how many more interesting homes would have eventually been built throughout the Berkshires if Randy was with us today.
(Special thank you to Wendy Darling and Greg Barriere, siblings of Randy Barriere for their input.)
June 16, 2025
Kumho Mitsui Chemicals begins operation of chlor-alkali plant using thyssenkrupp nucera technology
6/16/2025 2:00:00 PM
- Utilizing latest generation e-BiTAC v7 electrolyzers, thyssenkrupp nucera designed and supplied a chlor-alkali plant for Kumho Mitsui Chemicals (KMCI) in Yeosu, South Korea
- KMCI uses produced chlorine to replace imports of this raw material and to expand its Methylene Diphenyl Diisocyanate (MDI) production capacity
- New chlor-alkali plant also enables KMCI to recycle by-product brine from MDI production and to reduce its environmental footprint
Kumho Mitsui Chemicals (KMCI) has enhanced its production process of methylene diphenyl diisocyanate (MDI) by utilizing the latest generation e-BiTAC v7 electrolyzer technology from thyssenkrupp nucera. The supplier of world-leading technologies for high-efficiency electrolysis plants designed and supplied a chlor-alkali plant for KMCI in Yeosu, South Korea with a capacity of 60,000 tpy of chlorine production. Recently, the operation of the plant has been started successfully.
KMCI, a South Korean petrochemical company and a world-leading polyurethane maker, will use the produced chlorine for MDI production – replacing imported raw material of chlorine. MDI is an essential raw material for production of Spandex, TPU (Thermoplastic polyurethane), synthetic leather, shoes, paints, coating, adhesives, and various elastomers.
Furthermore, the chlor-alkali plant will recycle by-product brine from MDI production which is usually discharged as effluent. This enables KMCI to comply with stringent environmental regulations on industrial effluent in a cost effective manner and to reduce their environmental footprint. “The start-up of our new chlor-alkali plant is an important step to expand our production capacities and to secure an independent supply of MDI without importing chlorine. It also underlines our commitment to supplying eco-friendly products,” says Kwon Hyung Seob General Manager of KMCI.
thyssenkrupp nucera initially supplied a lab cell facility as a pilot test and verified the technical feasibility for operating the chlor-alkali plant with waste brine from MDI process. Afterwards, in 2021, the electrolyzer specialist was awarded an EP contract to design and supply the entire chlor-alkali plant. “Once again, our proven electrolysis technology made an important contribution to our clients’ path to improve their production processes and reduce their environmental footprint. By recycling by-product brine, KMCI and thyssenkrupp nucera have jointly addressed one of the major concerns of the polyurethane industry,” says Akira Shigeta, CEO of thyssenkrupp nucera Japan.
June 15, 2025
Mattress Retailers Optimistic After Successful Memorial Day
Memorial Day marks the start of the summer mattress sales season. And while no one knew how the holiday would look this year because of economic uncertainty, retailers we spoke with were satisfied with the results.
Vernon Williams, co-owner of Jacksonville Bedding, Mattresses and More, says his store’s Memorial Day sales were nothing short of incredible.
“Weekend sales were up 168%, and we saw a 312% increase for the month compared to last year,” he says. “Store traffic remained steady throughout the holiday, but what stood out was the higher average ticket size and the sheer volume of essentials and adjustable bases we moved. Customers came ready to invest in better sleep.”
That’s a theme that Michael Wipfler, director of sales at Mueller Furniture, saw as well. He says mattress business at the stores — two of which are in Missouri and the other two in Illinois — were up significantly compared to last year.
“Our average ticket was up as far as sleep systems go,” he says. “We were selling nicer sleep systems, and there wasn’t a rush of low-end sleep sales. We had a lot of people there to invest in their sleep, and that was great to see.”
Tim McDonald, general manager for At Home Furniture and Mattress superstore in Albany, Oregon, says door swings were down, but the tickets and number of serious buyers were “through the roof.”
“We ended up with a 42% increase over last year, which put us about $80,000 ahead of last year. And what’s crazy is last year we were about 28% mattress to furniture, and this year we were 46% mattress to furniture. I think the reason we had such great success is our selling top-down process. We fill the need, versus just selling furniture and mattresses.”
McDonald attributes the quality of sales to the brand’s marketing efforts.
We were marketing our high-end, quality product — $5,000 beds versus the $999 special. Everything was 75% off and our long-term financing was used by many.”
He says it seemed that more people were using financing this year than in the past because the tickets were so high. “We were turning opportunities for basic recliners into split-king mattress sales — $1,000 tickets into $7,000 tickets.”
For McDonald, May started slow, but for others, like Greg Jent, co-owner of two-store Discount Mattress Outlet in Bowling Green, Kentucky, May was a successful month. For one of the stores.
“We saw a 50% increase year over year at one store, and the other store stayed flat,” Jent says. “But the one that didn’t see the holiday increase saw a 100% month-over-month increase in May.”
While Jent says he kept his expectations low, he was pleasantly surprised with the turnout. “There’s a lot of uncertainty in the market, but I’ve talked to a lot of dealers and most of them were either flat or up,” he adds.
Jeff Giagnocavo, co-owner of Gardners Mattress and More in Lancaster, Pennsylvania, says the holiday brought 50% more sales year over year, which was record-breaking for his store.
“We continue to put out a consistent message and then support it with action and customer affirmation to invest in a quality set to wake up happy with reduced pain to get better sleep. We dug into that message this year, so I feel our advertising was probably stronger this year compared to last.”
He says May has always been a strong month for his store and that he anticipated success based on the popular DTC brands his store carries.
“Consumers recognize those names, and our advertising in addition to theirs creates awareness,” he says. “Consumers recognize big S brands but they don’t have the same connection to them as they do with DTC brands.”
The store’s advertising also focused on how financing makes things manageable, and Giagnocavo says that paid off.
“An adjustable Tempur-Pedic sets for 100 bucks a month with 60 months financing,” he says. “But we don’t want to force anyone to do it or get them into debt. We have an honest, upfront conversation about financing and it’s on the uptick.”
It’s still unknown if a successful Memorial Day is a sign of a positive summer selling season to come, but it’s not discouraging. Only time will tell.
SOURCE: Bedding News Now/Alex Milstein
nationwidesouthwest.com/2025/06/12/mattress-retailers-optimistic-after-successful-memorial-day/
June 13, 2025
China’s Foam Mattress Exports Demonstrated Resilience Due to Stable Demand in Jan-Apr
PUdaily | Updated: June 10, 2025
China exported a total of 9.975 million foam mattresses during January to April 2025, down 2.5% year-on-year. The export value was USD 236 million, a decrease of 3.2% compared to the same period last year, according to customs data. The declines in the two key indicators were both below 3%, demonstrating the industry’s resilience amid rising uncertainties. The total weight of mattresses exported from China during this period reached 47,900 tonnes, up 2.1% year-on-year, reflecting a slight adjustment in product structure and an overall stable demand.
| Foam Mattress Exports(Under HS Code 94042100) | Quantity (1,000 pieces) | Weight (1,000 tonnes) | Value (USD 100 million) |
| Jan-Apr 2025 | 9,974.80 | 47.9 | 2.36 |
| Jan-Apr 2024 | 10,226.30 | 46.9 | 2.44 |
| YoY Change | -2.50% | 2.10% | -3.20% |
China’s Monthly Foam Mattress Exports 2023-2025 (tonne)
From January to April, Japan was the first export destination for Chinese foam mattresses, with exports totaling 7,881 tonnes, up 5.2% year-on-year, accounting for 16.4% of China’s total exports.
Table 1: Top 15 Export Destinations for China’s Foam Mattresses (Jan-Apr 2025)
| Destination | Weight (tonnes) | Share (%) |
| Japan | 7,881 | 16.44% |
| USA | 7,146 | 14.91% |
| Germany | 3,974 | 8.29% |
| Mexico | 3,461 | 7.22% |
| Australia | 3,219 | 6.71% |
| France | 2,516 | 5.25% |
| UK | 2,037 | 4.25% |
| South Korea | 1,827 | 3.81% |
| Thailand | 1,103 | 2.30% |
| Poland | 1,083 | 2.26% |
| Others | 13,693 | 28.56% |
| Total | 47,940 | 100.00% |
Among these export destinations, traditional markets such as Japan, the USA and Germany made up 44.55% of the total exports (with the top three destinations combined to occupy 39.64% of the market share). Exports to Japan increased by 5.2% year-on-year to 7,881 tonnes, highlighting strong resilience in key markets. Although some market shares fluctuated slightly, the top 15 destinations accounted for over 70% of exports, indicating a stable market landscape and endorsing the robust demand for Chinese mattress products in the international market.
It indicates that China’s mattress industry could hold on in the face of an ever-changing global environment. Chinese manufacturers have made risk mitigation efforts to counter external uncertainties, such as retaining existing customer bases and optimizing product structure. The slight changes in export volume and value mostly reflect normal market fluctuations rather than a shift in demand trends. The fundamentals remain stable and strong.
Going forward, China’s mattress exports are expected to keep resilient amid stable recovery in global consumer demand. Chinese businesses should continue to focus on market needs and optimize supply chain, steadily increasing added value while maintaining cost advantages, thereby further enhancing market share and promoting sustainable industrial development.
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