Foamex Environmental Health & Safety
Foamex is committed to managing its operations so that all employees can work in a safe environment. Foamex is also committed to meeting the standards of local, state, and federal laws to ensure that the public and the environment are properly protected.
Foamexs Environmental Health and Safety Department is charged with providing leadership and support in meeting this core Foamex requirement. The Company-wide EHS Organization includes Plant EHS Managers, located strategically throughout the Company's manufacturing locations and the Corporate EHS Group, located at the Companys Headquarters in Linwood, PA.
Sustainable Development
Foamex has made environmental, health and safety considerations a leading priority in manufacturing existing products and for planning new products, facilities and processes. Our goal is to sustain ongoing reductions in the amount of contaminants released to air, water and land. The following examples provide an outline of the continuing efforts Foamex has initiated.
Recycling
Foamex recycles almost 100% of the foam byproduct generated from our prime foam manufacturing process. We have integrated our material handling process throughout our network of manufacturing locations, which enables us to use recycled foam as a raw material in our rebond carpet pad. The foam component of our rebond carpet pad is made from 100% recycled foam, including post consumer trim, which would otherwise be disposed of.
Foamex is part of a network of foam recyclers, located throughout the United States, providing an outlet for commercial carpet installers to recycle foam carpet pad removed from residences and commercial buildings. In addition to recycled foam generated internally from our manufacturing operations, Foamex purchases scrap foam and post consumer trim on the open market. Foamex processes approximately 260 million pounds of recycled foam each year.
Reducing Hazardous Air Emissions
Foamex is committed to environmentally responsible foam manufacturing. The Company has made significant progress in the reduction of hazardous air emissions, specifically, methylene chloride, a United States Environmental Protection Agency Regulated Hazardous Air Pollutant (HAP).
The patented Variable Pressure Foaming (VPFSM) Technology utilized by Foamex sets the standard in environmentally responsible foam manufacturing. In fact, VPFSM is the most environmentally friendly process for the manufacture of polyurethane foams worldwide. The closed chamber reduces the need for auxiliary-blowing agents required in traditional foam production, and maximizes our ability to control process emissions.
VPFSM enables us to develop and produce unique, value-enhancing products for our customers, while providing higher yields from raw materials than traditional foaming methods. This combination of superior product performance and reduced air emissions provides an important technological edge for Foamex. Foamex operates four VPFSM facilities throughout the United States.
Compared to standard foam production methods, VPFSM technology exceeds the Clean Air Act Requirements. The most beneficial advantage of the VPFSM manufacturing process is that the physical properties of the polyurethane foam are controlled through the use of pressure rather than chemicals, allowing Foamex to reduce its use of methylene chloride.
The VPFSM method of manufacturing is beneficial to Foamex employees at our manufacturing facilities. Minimizing methylene chloride use reduces the possibility that Foamex employees will be exposed to the hazardous substance. Continuous employee air monitoring provides data to support the fact that VPFSM is contributing to a safe work environment.
Starting in 1999, Foamex made a concerted effort to substitute and/or eliminate methylene chloride use in our foam production process. Over the last five years, Foamex has succeeded in reducing methylene chloride emissions by 85%.
