Foamex Expands Exclusive Foaming Process to East Coast

    CORNELIUS, N.C.--April 5, 2001--Foamex International Inc. today held a ribbon-cutting ceremony to mark the official start-up of the company's Variable Pressure Foaming (VPFSM) manufacturing facility at its plant in Cornelius, N.C.
    The Cornelius installation is the third Foamex VPF facility in the United States, and one of only six in the world.
    VPF is a proprietary, environmentally friendly manufacturing process which produces foam continuously in an air lock chamber. John Televantos, President and Chief Executive Officer of Foamex, explained, "The closed chamber eliminates the need for auxiliary blowing agents required in traditional foam production, facilitating cost-effective compliance with impending environmental regulations. The technology 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 regulatory compliance means an important technological edge for Foamex, which has exclusive manufacturing rights to VPF in North America.
    Pete Wallace, Executive Vice President, Foam Products East, commented, "Adding VPF capability to our production capacity in the east will particularly benefit our furniture and bedding customers in that region by increasing their access to just-in-time delivery of the broadest array of value-added cushioning products in the industry."
    A significant portion of the new VPF capacity at Cornelius, which is near Charlotte, will be dedicated to production of the company's Reflex(R) line, a family of advanced furniture cushioning products that provide specialized support for upholstered furniture. "Acceptance of the Reflex line by the furniture industry has created high demand for the entire line, but especially for Reflex HR(TM), the newest member of the family," Wallace said. "Reflex HR sets a new standard in HR foam luxury, comfort and performance. It also provides greater styling flexibility and extended durability in the construction of upholstered furniture. Customers throughout the Carolinas are excited that we will be producing this innovative new product in Cornelius."
    The Cornelius line will also produce Quiltflex(TM), a revolutionary new bedding foam developed by Foamex and currently produced at its Orange, Calif. VPF facility. "Quiltflex has the plush feel of polyester fiber with significantly improved durability," Wallace said.
    Quiltflex is currently being test-marketed for use as a top layer in mattresses, and also has application in quilts, comforters and pillows. Expanding production from California to North Carolina will significantly expand the geographic reach for Quiltflex.
    A third product category enabled by VPF technology is Spectrum(R), a protective packaging material that provides improved product protection with less material and lower weight than conventional urethane. Spectrum provides the packaging industry with a creative new material with benefits that apply throughout the supply chain, from manufacturer, through the customer and up to OEMs.
    These are just a few examples of the exciting product potential offered by the combination of Foamex's proprietary formulas and VPF technology. Vincent A. Bonaddio, Senior Vice President, Technology for Foamex, noted, "We are experiencing strong demand for VPF-based products for the bedding, packaging and furniture markets, and we are now developing superior new products to serve the automotive interiors, flooring underlay and specialty markets."
    With this newest installation, Foamex now operates three VPF manufacturing facilities representing nearly thirty percent of its total foam manufacturing capacity in North America. In addition to the Cornelius plant, Foamex has VPF facilities in Tupelo, Miss. and Orange, Calif. The company also has announced plans to install a VPF line at its facility in Auburn, Ind., which is expected to be operational in the second half of this year.