By Liz White, UT staffArchdale, North Carolina-Sealy Mattress Corp., which claims to be largest bedding manufacturer in the world, has reported that the general shortage of polyurethane foam after the Gulf Coast hurricanes in the US did not have a "material impact" on its financial results for the year. Reporting net sales for the year ending 27 Nov 2005 of $1469.6 million, Sealy said gross profit was $651.6 million or 44.3 percent of sales as compared with $573.9 million or 43.7 percent, a year earlier. Net income was $73.7 million or 5.0 percent of sales, compared to a net loss of $38.3 million for fiscal 2004.While the Gulf Coast hurricanes "caused a significant temporary disruption to the supply of an essential raw material used to manufacture polyurethane foam" [toluene diisocyanate], Sealy said it suffered only limited impact on its foam supply. A temporary foam shortage, experienced by many North American manufacturers, also affected Sealy's production schedules for all its North American mattress plants, for some four weeks in the fourth quarter, the firm admitted. But by re-prioritising schedules and finding alternative foam sources, Sealy said it "successfully limited the impact of this disruption," resuming normal schedules by the end of October. "