Leesa Shifts to Plant-Based Foam Production in Arizona

The shift toward biobased polyols marks a departure from standard industry practices, which typically rely on oil-derived inputs. Unlike conventional soy-based foams that require energy-intensive chemical processing, GreenFlex utilizes a more efficient conversion method, capturing roughly 45% of oil extracted from crops grown on marginal land. By keeping production in-house, the company eliminates the carbon footprint associated with shipping foam from third-party suppliers.

This material now carries a USDA Certified Biobased Product label, alongside CertiPUR-US and GREENGUARD Gold certifications. It features an open-cell architecture designed to manage heat and pressure, and it is currently integrated into the majority of the Leesa product lineup. This manufacturing pivot builds upon the company’s existing sustainability initiatives, which in 2024 reportedly diverted 3.9 million pounds of foam scraps and reduced shipping-related CO₂ emissions by over 3,400 metric tons. Prices for the updated mattress series begin at $669.