NCFI Breaks Ground on $50M+ NC Plant Due to Surging Demand

June 26, 2025 – Mount Airy, NC – NCFI Polyurethanes, one of the nation’s leading manufacturers of polyurethane foam, has broken ground on a new $50M+, 140,000- square-foot manufacturing facility in Mount Airy, North Carolina. 

The ceremony, held in partnership with the Surry County Economic Development Partnership, brought together local officials, business leaders, and community stakeholders to mark the beginning of a major new chapter for both the company and the region.

“NCFI is proud to double down on our commitment to Mount Airy, the community we’ve proudly called home for over 60 years,” said NCFI President Chip Holton. “This new facility represents a critical step forward in meeting the rapidly growing demand for spray polyurethane foam (SPF)—a market that’s increasingly driven by sustainability and energy efficiency. With this expansion, we’re not only increasing our capacity but also reinforcing our position as a leading U.S.-based, independent supplier of foam for insulation, roofing, geotechnical, and aerospace applications.

The new facility will complement NCFI’s existing operations in North Carolina and Texas, creating additional manufacturing flexibility and resilience across its supply chain.

“At a pivotal moment when NCFI could have expanded elsewhere, the leadership team chose to invest right here,” said Lewis Barnhardt, President and COO of Barnhardt Manufacturing Company, NCFI’s parent company. “That choice speaks volumes about the company’s values and the strength of its roots in Mount Airy. This reinvestment benefits not just the business, but the entire community.”

Mount Airy Mayor Jon Cawley echoed that sentiment, highlighting the company’s long-standing impact: “For more than six decades, NCFI has been an economic cornerstone of this region. Today’s groundbreaking ensures they’ll remain a vital part of our story for decades to come.”

NC State Representative Sarah Stevens also praised the company’s role in supporting local families: 

“NCFI is a national leader in sustainable building materials—and here at home, they provide dozens of high-paying jobs that help strengthen our community.”

Founded in 1964 as North Carolina Foam Industries, NCFI operates with a mission to produce the world’s highest quality foams. Headquartered in Mount Airy, NCFI maintains facilities in both North Carolina and Texas and is a proud member of the Barnhardt Manufacturing Company, a fourth-generation family-owned business.

Contact Dale McGlothlin for more information (202) 341-8615.

dm@seachangeglobal.com

Published by Spray Foam Magazine

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