Manufacturing

INSIDE

Manufacturing

Our manufacturing philosophy is to embrace every job with the question.

“How can we do this better?” We are passionate about building the most effective manufacturing lines in the foam industry – ensuring flawless quality, on-time delivery, and the reliable supply of our broad range of technologies. Our in-line 3D cutting tools provide consistency and precision for optimum design – every product, every batch. Our operations and supply chain teams work relentlessly to ensure that our foams are made in a safe, environmentally-responsible, efficient and cost effective manner in our plants across the nation. With every action and improvement, we strive to enhance our abilities as a reliable, flexible and trusted partner for our customers.

We are proud to manufacture all of our foam products in the USA – ensuring lower shipping costs, faster deliveries, shorter lead times and higher quality. Because this commitment resonates strongly with consumers, our USA-made foams can help enhance the brand reputations of end-use products across a wide array of industries.

Inside our robust manufacturing network, we guarantee you’ll find the solutions you need, exactly where and when you need them. Your world moves quickly, and so do we.

Our Network

Our USA-based manufacturing network combines the efficiency advantages of a large company with the personalized attention to detail you would expect from a local partner. Wherever you are, our team is on-hand to deliver the precise foam solutions you need.

  • Red Bank, NJ
  • San Bernardino, CA
  • Miami, FL
  • Dublin, GA
  • Dubuque, IA
  • West Chicago, IL
  • Elkhart, IN
  • Newburyport, MA
  • Lebanon, MO
  • Baldwyn, MS
  • Coldwater, MS
  • Tupelo, MS
  • Highpoint, NC
  • Spencerville, OH
  • Archbald, PA
  • Dunmore, PA
  • Chattanooga, TN
  • Brenham, TX
  • Terrell, TX
  • Longview, WA
  • Portage, WI

Capabilities

From tackling your biggest challenges to satisfying your critical daily needs, our team is agile and passionate about meeting your unique speed, quality and specification requirements. Our extensive, world-class foam portfolio offers a broad range of innovative solutions that offer unbeatable comfort and protection abilities across diverse markets, including bedding components, furniture, sound protection and packaging.

Every site in our nation-wide network has cross-functional capabilities – granting our customers a huge amount of flexibility and reliability, even in the face of an unplanned event. We are experts at short and long-term planning, allowing us to be nimble and responsive in the fast-paced industries we serve.

We are constantly thinking about tomorrow’s challenges today, both from a technology and a supply chain standpoint, and we thrive on continual evolution. Nothing makes us happier than when a customer calls to say, “Can you help me with this?” Your challenges inspire us, and we live to push the envelope on what we can deliver – and to continue enhancing our core capabilities and our strength as a trusted partner and solutions-provider.

Mattress-In-A-BoxFind out more about our Mattress-In-A-Box

Environmental Promise

Our commitment to serve as a trusted, environmental steward in the communities in which we operate influences everything that we do. Whether we are developing a new technology, implementing a breakthrough process or choosing a new supplier, we maintain a crystal clear mindset: to always consider the environmental impact of our actions. This commitment means thinking long-term and creatively about solutions that enhance both our business and our environmental goals. It means working collaboratively and partnering with both our suppliers and customers to set even higher standards. It means doing the right thing. Every day.

Through our robust Environmental Audit program, we conduct both internal and external environmental audits to ensure that we are meeting – or surpassing – all regulatory requirements. All of our foam is manufactured using an environmentally-friendly, state-of-the-art foam pouring process, and our CertiPUR-US® certification recognizes that our products require low-emissions for indoor air quality and are made without ozone-depleters, formaldehyde, PBDE’s, prohibited phthalates, lead, mercury and other materials of concern. Our Internal Foam Scrap Program and Customer Scrap Buy-Back Programs are going strong. We are also a proud member of the Polyurethane Foam Association, which works together with regulatory agencies and environmental groups to ensure public health and safety by meeting the challenges posed by advancing scientific knowledge and environmental policies.

At Innocor Foam Technologies, our commitment to the environment will always be a journey of continuous improvement. Today. Tomorrow. And for a brighter, better future.

Operational Excellence

For our team, operational excellence isn’t a methodology; it’s a mindset. We know that our customers’ needs aren’t confined to just our physical products; they also depend on us to deliver an exceptional level of quality and reliability in every aspect of our partnership. Every day, we follow – and even pioneer – the industry’s most innovative practices and technologies in operational excellence to ensure that we are the most reliable, efficient and flexible partner possible for our customers.

Inside our culture of operational excellence, you’ll find a team of well-trained problem-solvers – and, more importantly, problem-preventers! Through extensive, world-class training, we have built a team of top-notch, quick-thinking experts who apply their manufacturing expertise towards achieving challenging targets, meeting stringent specifications and aiming to surpass all customer expectations.

Our operational excellence culture is strengthened by the principles of Lean Manufacturing and Six Sigma, and supported by our journey to world class Total Productive Maintenance (TPM) program. We are dedicated to seeking new ways to remove both scrap and waste from our processes – enabling cost savings for everyone in the value chain. Our automated fabrication, maximized production flow, high yield scheduling, and JIT inventory management ensure that our products deliver on schedule and run flawlessly on your equipment – every product, every time.

Quality Assurance

As a world class organization, our quality promise to our customers is simple: do the job right – every single time. We don’t cut corners, and we strive to be the best we can be in all that we do – and to exceed our customer’s expectations by providing the right product, at the right time, in the right quantity, and of the right quality.

Our key sites are International Standardization Organization (ISO) 9001:2008 certified, and we are pursuing certification in ISO 9001: 2015. Our commitment to these industry-leading standards is integrated into our every practice and undertaking. This commitment is supported by our robust Quality Management System (QMS), which enables us to track and measure our results – and adjust as needed – to maintain our world-class record in reliability and flexibility. In addition, we adhere to all ASTM national measurement standards in our testing procedures, and our critical processes of foam pouring are controlled, measured and continuously improved through Statistical Process Control (SPC) to minimize variation and ensure that we are always operating at our full potential. We are also CertiPUR-US® certified, meaning that our processes meet all requirements for low-emissions for indoor air quality, and our products are made without ozone-depleters, formaldehyde, PBDE’s, prohibited phthalates, lead, mercury or other materials of concern.

While we are very proud of our certifications and strict adherence to industry-recognized standards, we are even prouder of the exceptional quality culture that lives in our core, flavoring every facet of our work – driving us to push beyond certifications to exceed expectations. Every member of our team plays an integral role in this culture, from our Six Sigma black belts to our broad range of experts in Lean Manufacturing. Our empowered team works as a unified whole to fine-tune our every process to ensure that we constantly deliver the service you expect and the superior quality you trust.

Safety

Our commitment to safety is more than just a series of programs; safety is a core component of our culture, and it guides all that we do and every decision we make. From our executive offices to the manufacturing floor, our focus on safety touches every corner of our organization. As a team, we may all have very different roles, but we share the same top priority of ensuring that each and every one of us returns home safely – day after day, and year after year.

Our rigorous Safety Audit program involves employees at all levels and ensures that we meet all regulatory requirements and uncover any opportunities for enhancement. In 2015, we improved our Injury Rate by 30% and our Lost Time Injury Rate by 50%. While our constant safety target is zero injuries – because even one injury is one too many – we are very proud of the tangible improvements we have made as a collective team over the past few years. In particular, our High Point plant in North Carolina recently hit an impressive milestone of three years injury-free, and the site team has been recognized for their efforts by the NC Department of Labor with a Gold Safety Award.

At our very core, we believe that safety is a dynamic, life-long learning process, and through excellent training and ongoing dialog, we are all empowered – and encouraged – to speak up if a safety hazard is identified or to share a suggestion for improvement. This razor-sharp focus on safety is a core commitment we make every single day – to ourselves, our colleagues, our families and the communities in which we operate.