Optimizing Assets, Efficiency, and Margins through Mannich Polyol Consolidation

As competitive intensity continues to increase in the polyurethanes industry, the Global Operations team has continued to evaluate opportunities to improve efficiency across the manufacturing footprint. In line with this goal, a cross-functional team assessed multiple Huntsman locations to identify the optimal production strategy for two polyols supplied to the Huntsman Building Solutions (HBS) business. That work identified an opportunity to consolidate production of both polyester and Mannich polyols at the company’s Houston Port facility and strengthen long-term operating efficiency.

Houston Port offered several advantages, including its existing supply position to HBS sites, minimal impact to the overall site risk profile, long-term operating sustainability and supply dynamics. The team was tasked to design, construct, and commission Mannich polyol production at Houston Port, with the objective of transitioning an existing polyester polyol reactor (historically dedicated to TEROL ® ) to produce Mannich. Transitioning this asset required close collaboration among the site team, the Global Excellence Team (GET), the Huntsman Advanced Technology Center (HATC), and Environmental, Health and Safety (EHS) teams.

To date, the team has delivered on the following initiatives:

• Improved fixed cost performance by consolidating HBS polyol production from three sites to two
• Reduced the PSM and environmental risk
• Added TEROL ® and Mannich polyol production capability at Houston Port through reactor modifications, solids charging, and new tank storage
• Worked closely with Purchasing, GET, EHS, and T&I to support fast project execution and help ensure product quality, compliance, and safety standards.

The project began in January 2025, with successful product manufactured in October 2025. The HBS organization is now fully supplied for PDS-100 and Mannich polyols.