In re Polyurethane Foam Antitrust Litigation

314 F.R.D. 226, 2014 WL 11199430
District Court, N.D. Ohio·Decided April 9, 2014·No. Case No. 1:10 MD 2196·Published·Cited by 12 cases

Opinion

[229]*229 CLASS CERTIFICATION MEMORANDUM OPINION AND ORDER

JACK ZOUHARY, U.S. DISTRICT JUDGE

Introduction

In these consolidated proceedings, two putative classes allege that dominant firms in the flexible polyurethane foam market engaged in a decade-long conspiracy to fix, raise, and maintain the price of foam products. Pending before this Court are Motions for Class Certification by two groups of plaintiffs: Direct Purchasers (Doc. 584) and Indirect Purchasers (Doc. 577). Defendants opposed the Motions (Docs. 680, 682, 683 & 686), and Plaintiffs replied (Docs. 740, 741 & 744). The parties papered the docket with numerous expert reports (Does. 581-83, 584-10 at 22-42, 584-14, 590, 594, 679-1, 680-1, 682-1, 682-2, 683-2, 743, 744-13, 744-48, 744-49, 752, 892-1, 892-2, 892-3 & 893-1). (Other parties in this case, Direct Action Plaintiffs, proceed separately from the putative classes.)

This Court then held oral argument on both Motions, and heard testimony from several experts — Leitzinger, Lamb, Ordover, and Burtis (Docs. 898, 938, 954, 957, 959-60 & 967). There is more. The parties engaged in a parade of filings with post-heating supplemental authorities and other materials covering a range of topics (Docs. 963-64, 985, 990, 1020, 1024, 1031, 1035, 1085-86 & 1098). After an exhaustive review of the record, this Court grants both Motions for the reasons that follow.

Background

The Parties and Products

Polyurethane Foam. Market

The polyurethane foam (“foam”) market consists of several types of products. Foam [230]*230products are created from a mixture of toluene diisocyanate (“TDI”) and polypropylene glycol (“polyol”) (Doc. 584-14 at 10; Doc. 581 at 13 (explaining “all of the TDI produced in the United States” is used in foam production); Doc. 682-1 at 37; Doc. 680-1 at 40). Pricing for each chemical is influenced by petroleum prices (Doc. 682-1 at 41-42 (quoting a Foamex SEC filing attributing foam input price increases to “oil and natural gas prices and the current geopolitical instability and its impact on oil production and prices”)). The principal chemical manufacturing plants for TDI and polyol, run by industry-dominant firms like Lyondell Chemical Company (now LyondellBasell Industries), Huntsman, Dow, and BASF, are or were located in the Gulf Coast region (Doc. 682-1 at 40-41; Doc. 680-1 at 43-44; Doe. 584-14 at 44 n.226). Together, these two chemicals account for roughly ninety percent (90%) of foam production costs (Doc. 584-14 at 10 (estimating TDI and polyols to be “80 to 90 percent of slab-stock manufacturing costs”); Doc. 581 at 13 (same); Doc. 682-1 at 38 (quoting various Defendants’ internal cost-share estimates from 85 to 90 percent of aggregate cost); Doc. 680-1 at 41)).

Water also figures in the foam blend, serving as a “blowing agent” that produces an exothermic reaction in the foam blend causing it to expand (Doc. 680-1 at 40). Product-specific additives, discussed below, are important in determining foam type. But, like water content, the cost of these additives does not cause large variations in the cost of producing foam products of comparable foam volume — TDIs and polyols are dominant throughout.

From here, production processes and alterations to the general foam blend effectively split the generic foam market into “sub-markets.” Some foam, termed “rigid,” is used for building or automotive insulation (see Doc. 680-1 at 38 (noting Woodbridge’s production of rigid foam products); Doc. 581 at 12 (noting that rigid foam accounts for 46 percent of polyurethane foam demand, with the remainder tied to flexible foam)). “Molded” foam, primarily found in automobile cushions, is formed after the foam blend is “poured into custom tooled molds the shape of the desired product” (Doc. 680-1 at 40-41). Foam is near ubiquitous, appearing in a vast array of product uses. “Packing peanuts,” for example, derive from the same general foam blend (Doc. 682-1 at 51). Flexible foam alone amounts to 1.2 billion pounds per year in domestic consumption (Doe. 581 at 13).

But the present Motions, while broad in scope, do not encompass the entire foam industry. Rather, only two foam sub-markets, distinguished from other sub-markets by their production processes and end uses, are relevant: slabstock and underlay.

Slabstock

As noted above, the foam blend undergoes an exothermic reaction with the addition of a blowing agent, typically water; that reaction generates a release of heat, forming bubbles within the foam blend. “The bubbles in the foam produce ‘cells’ containing air” (Doc. 682-1 at 37; Doc. 680-1 at 40). For slab-stock, the expansion process occurs as foam is continuously “poured” onto a moving conveyor belt (Doc. 584-14 at 9). That conveyor belt is equipped with “sides from [three to four feet] high” (Doc. 581 at 13), with length and width dimensions that vary depending on intended uses (Doc. 584-14 at 9 & n.16). Cured slabstock, which resembles a loaf of bread, is also referred to as a “bun” (id. at 9 & n.15).

But not all slabstock is created equal. Foam manufacturers regularly vary foam blends to produce varying characteristics or “grades” (see id. at 15 (noting combustion modifiers and other additive types)). Slab-stock can vary by density, with more dense foam typically providing better support and comfort (Doc. 682-1 at 47; Doc. 680-1 at 50). Slabstock can also be more or less firm, measured according to an industry-standard Indentation Force Deflection calculation (Doc. 584-14 at 17; Doc. 682-1 at 48; Doc. 680-1 at 51). “Support factor,” a measure of “deep down support,” can also be adjusted in the production process (Doc. 680-1 at 51), as can resilience or springiness, a quality measured by dropping a steel ball onto foam and measuring the ball’s rebound height as a percentage of the drop height (Doc. 584-14 at 19). The paities identify other ways slab-stock can vary (see, e.g., id. 18-19 (describ[231]*231ing hysteresis, flex fatigue, roller shear, tear strength, air flow, and combustibility qualities of slabstoek and how those qualities are measured)). These characteristics “are determined by the specific formulation of chemicals that are combined to produce [the foam], and are largely independent of each other,” such that high resilience foam can be more or less dense (Doc. 680-1 at 52).

Slabstoek with a given set of characteristics may vary by form (see, e.g., Doc. 682-1 at 49). A bun can be sold in the same form in which it leaves the conveyor belt (Doc. 584-14 at 20). Or, extending the industry’s apparent penchant for baking metaphors, a bun can become a “roll” by slicing the bun lengthwise and then winding the resulting foam sheets into a roll. Or a bun can be otherwise fabricated, either by the bun manufacturer itself or by another firm, through various post-pouring technologies “involving] combining foam with another material, such as a nonwoven substrate or fiber,” or joining foam types together (id. at 21).

Underlay

Underlay, or carpet cushion, is produced in two primary forms. Most commonly, underlay is composed of “rebond” (id. at 23). Re-bond joins together slabstoek “scrap” or “trim” generated during the fabrication process — for example, the waste material created in the course of cutting a bun to some desired shape. The scrap is shredded further, and then combined in a mold with a binding agent.

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In re Polyurethane Foam Antitrust Litigation, 314 F.R.D. 226, 2014 WL 11199430 (N.D. Ohio 2014).

314 F.R.D. 226 (In re Polyurethane Foam Antitrust Litigation) — published by Counsel Stack Legal Research, free access to 12M+ legal documents.

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