The Foam Saga: The Mexican Chapter

Despite one hell of a ride, the foam saga is not over. Thus far, though, we have endured the initial shock of Clark’s closure and the surfboard manufacturing industry’s frantic efforts to jumpstart itself after being ripped from its lifeline. Rumors circulated about factories popping up here and there, one of those places being none other than our neighbor to the South. But those weren’t rumors. A year after Clark’s closure, a handful of foam companies are, in fact, in full operation in Mexico.
The companies -- Bennett Foam, Surf Blanks America, and King Mac -- are not only in full effect, but they are strong competitors in the fight for domination of the foam market.  
King Mac Enterprises, in particular, was said last year to be in the running to become the global forerunner in the surfboard manufacturing market, according to a Surfing Magazine online exclusive. After opening the doors of their 28,000 square foot Tijuana factory built from scratch in March of 2006, they were looking to supply the market with 20,000 blanks a month, a significant figure and comparable to the 25,000 to 30,000 produced by Clark foam a month.  
Now, a year of production has passed, and while they are not volunteering numbers, Seth Bishop, King Mac’s San Diego Distributor says, “We are able to comfortably supply Southern California, Japan, Hawaii, and Costa Rica if that can give some sense of our production.”  And, according to King Mac’s President Michael Sutherland, their percentage of the market continues to grow as other companies are being weeded out.
Sutherland says that the response from shapers has been positive, many reporting back that the foam is agreeably firm and easy to shape.  Their blank is produced from a formula that was created from the joint efforts of Rod McDonald of South Africa and Graham King of Australia, which has been in production for more than 30 years.  They are also working with a second custom order formula for what is preliminarily being called the “Springboard blank.”  The blank has different chemistry which allows for a more dynamic flex pattern and better memory.
Bennett Foam USA is another of the contenders for the foam market.  Working with a formula known as “Bennett A & B” manufactured in Australia by Dion Chemicals (a division of Bennett Australia), Bennett Foam markets their blanks for their whiteness, small cell structure, consistent density, strength, and lightness.  Their foam has attracted the attention of reputable shapers such as Rusty and Terry Martin, who have contributed design plugs.  They are currently working on bringing other well-known shapers from the East Coast, West Coast and Hawaii on board for design plugs for future mold production.
Last April, Bennett Foam USA began building their Ensenada factory, and production began in late June.  It is run by Debbiy Riegle and her brother Marty Gilchrist, who, as a former key player at Rip Curl, is no stranger to production in Mexico.
“My brother ran Rip Curl in Ensenada, and the biggest reason we went down there is that he was really impressed with the labor,” said Riegle. “The cost factor is a lot lower, the wages are a lot lower, and we have a really good staff.”
From a business standpoint, it’s obvious why these companies want to produce in Mexico.  It comes down to two words: low overhead.  With rent and labor factors much cheaper, the overall cost of running a factory is significantly less.
But what about environmental regulation?  Did the stories of Clark’s run-ins with environmental agencies send these companies running for the border?  Are they trying to avoid being hassled by the Environmental Protection Agency or the Occupational Safety and Health Administration?
Bennett Foam USA and King Mac state clearly that this is not the case.  
“We still run our factory under the same EPA guidelines as if we were producing in California.  We do the same protection,” said Riegle.  “My kids are often around when we are pouring.”
A factory in Enseneda was even the birthplace of Glory Foam, which is now producing in the United States.  Created by Tom Brown and his wife Richelle Brown, Glory Foam strives to create a more eco-friendly board.  Their PUR-Foam product utilizes a safer MDI technology, rather than the extremely toxic TDI chemical normally used in producing foam.  Glory Foam has also innovated a process to produce blanks more efficiently and with less waste through the use of a computer controlled dispensing machine and the elimination of the need for release papers.
The fate of the post-Clark foam industry remains to be seen.  But if shapers turn to these companies producing blanks in Baja as their dominant foam providers, you better get used the to the “Hecho en Mexico” stamp on your blank.

How important is where a blank comes from?

“I would say that it is more important to have good plugs.” Wally Puha, Chemistry Surfboards

“Well, frankly, I really think that it is service that is a major factor.  It is about having the blanks accessible.”  Mike Eaton, Eaton Surfboards.

"After Clark closed their doors, I made up my mind that I didn't care where it came from, just as long as the people behind it were good people with it was a good product.  I don't mind buying products from Mexico." Dennis Murphy, Murphy Surfboards

"It is very important because we are not supporting the China market. We are 100% American made surfboards."  Paulo Cabral, Marbella Surfboards

"It is not necessarily where it comes from, but rather the quality of the foam."  Hamish Graham, Super Stix