Product Stewardship Institute Mattress Industry Overview Mattress Initiative Mattress Industry Overview April 11, 2011 Connecticut Resources Recovery Authority Trash Museum 211 Murphy Road Hartford, CT

Industry Structure Most mattress producers are independent from retailers Some sell directly to consumer Some mattress producers make own springs and foam

Industry Concentration Plant Location Most mattresses made locally or regionally, minimizing shipping distances Industry Concentration Relatively non-concentrated Largest 5 national brands control about 60% of market Others are smaller national brands and independents Strategically locating future mattress recycling centers in urban areas, taking advantage of efficiencies possible using retailer distribution networks to collect/deliver used mattresses

Corporate Structure National brands: Corporate-owned plants Franchise structure with plants owned by 3rd parties Hybrid of corporate-owned and franchised plants Independent producers: Often multi-generation family-owned enterprises Public corporations: Only 4 mattress brands are public companies (although many components suppliers are publicly traded)

Most producers are small businesses Number of Employees Percentage of Industry 1-30 18.1 31-50 24.6 51-100 31.1 > 101 26.2

Industry hit hard by recession … 2005-2009 Sales: Strategically locating future mattress recycling centers in urban areas, taking advantage of efficiencies possible using retailer distribution networks to collect/deliver used mattresses …with companies closing and industry consolidating

Typical US mattress manufacturing process Assembly processes include sewing, gluing, nailing and fastening Virtually all US-sold mattresses/foundations assembled in US (94% in 2009) Components are primarily made in US, with some imports Most mattresses are assembled from components purchased from third party vendors

Mattress constructions Conventional innerspring mattress: Uses steel innerspring in mattress core, surrounded by foam or fiber All foam mattress: Can be made of latex foam or PU foam (including visco-elastic foam) Air mattress: Except for camping mattresses, most air mattresses have air bladder for core, surrounded by upholstery material Water bed: Uses water-filled bladder as core Hybrids: Combination of 2 or more of these systems (e.g., springs + memory foam, etc.)

Foundation constructions Most are stationary systems that use a wooden frame to support a steel wire unit Some stationary systems use all wood components Small but growing numbers of foundations are adjustable

Primary Materials Used Steel wire (both for mattresses and foundations/box-springs) Foam Flexible polyurethane foam (including visco-elastic foam) Latex foam Natural and synthetic fibers and fabrics (in woven, knitted and non-woven form) Air bladders and compression equipment for air beds Wood (for foundation frames)

Mattress industry’s current use of renewable materials Foam: Plant-based materials used in PU foam (polyols derived from soy and castor beans) and latex foam (tree-harvested latex rubber) Natural fiber: Mainly cotton, but increased amounts of wool, and limited amounts of other animal hair, silk, bamboo fiber and coconut materials Plant-based synthetic fiber: Rayon Wood: For foundations Will require – Large volume of used mattresses Equipment to separate/bale reclaimed components efficiently Markets for the recycled materials

Mattress industry’s recycling objectives Ongoing effort to build national infrastructure for recycling used mattress components Recyclable materials include: Steel springs: Recycled into new steel products Foam: Converted into carpet pads Fibers and fabrics: Used in filtration media Wood: Used as landscaping mulch, animal litter and fuel ISPA has identified 30+ mattress recyclers throughout North America Will require – Large volume of used mattresses Equipment to separate/bale reclaimed components efficiently Markets for the recycled materials

Mattress industry’s new product environmental footprint The US mattress industry EACH DAY sells the equivalent of a mountain of mattresses 20 miles high Will require – Large volume of used mattresses Equipment to separate/bale reclaimed components efficiently Markets for the recycled materials

Next Steps Involve retailers in collecting and promoting mattress recycling Create strategic partnerships to identify additional mattress recycling opportunities and technologies Support new markets for recycled components Develop mechanisms to fund new recycling centers Will require – Large volume of used mattresses Equipment to separate/bale reclaimed components efficiently Markets for the recycled materials

On-going sustainability efforts Minimize and recycle industrial scrap Avoid “green-washing” Local/regional manufacturing minimizes shipping Minimize packing materials Used mattress recycling to reduce consumer health, safety & fraud risks from unscrupulous “renovators” Will require – Large volume of used mattresses Equipment to separate/bale reclaimed components efficiently Markets for the recycled materials