Polyurethane Catalyst Market

Market Definition

The polyurethane catalyst is a chemical additive that accelerates and regulates the reaction between polyols and isocyanates during polyurethane production. They are crucial in controlling reaction speed, product quality, and the final material's physical properties. 

The market includes various product types such as amine catalysts, metal / organometallic catalysts, bismuth and other catalysts, and other specialty types, each tailored to specific reaction profiles and performance needs. 

The market is further segmented by function, covering gelling catalysts, blowing catalysts, curing catalysts, foam stabilizers, cross-linking catalysts, and others, depending on their role in polyurethane formation.

Polyurethane Catalyst Market Overview

The global polyurethane catalyst market size was valued at USD 2,543.2 million in 2024 and is projected to grow from USD 2,680.1 million in 2025 to USD 4,053.3 million by 2032, exhibiting a CAGR of 6.09% during the forecast period. 

This growth is due to the rising demand for catalysts driven by the expansion of polyurethane production facilities across industries such as construction, automotive, and furniture. The market is also witnessing a shift toward the adoption of polyurethane systems for battery protection in electric vehicles, as manufacturers seek lightweight, durable, and thermally stable solutions.

Major companies operating in the polyurethane catalyst industry are Huntsman International LLC, BASF, Shepherd Chemical, Gulbrandsen, Tandy Innavative Chemicals, Elé Corporation, Everchem Specialty Chemicals, Reaxis Inc., San-Apro Ltd., Milliken & Company, PATCHAM, TIB Chemicals AG, DURA Chemicals, Inc., UMICORE NV, and LANXESS.

Manufacturers are focusing on developing customized catalyst systems that align with evolving application needs and regulatory standards. They are prioritizing innovations that enhance reaction control, reduce emissions, and improve overall process efficiency. 

This approach supports the production of high-performance polyurethane products while enabling better compliance with environmental and safety norms across key markets.

Key Highlights:

1. The polyurethane catalyst market size was recorded at USD 2,543.2 million in 2024.
2. The market is projected to grow at a CAGR of 6.09% from 2025 to 2032.
3. North America held a market share of 34.15% in 2024, with a valuation of USD 868.5 million.
4. The amine catalysts segment garnered USD 727.4 million in revenue in 2024.
5. The gelling catalysts segment is expected to reach USD 1,188.1 million by 2032.
6. The flexible foam segment is projected to generate a revenue of USD 1,694.0 million by 2032.
7. Asia Pacific is anticipated to grow at a CAGR of 6.89% over the forecast period.

Market Driver

Growing Demand for Catalysts from Expanding Polyurethane Production Facilities

The growth of the market is primarily fueled by the growing demand for catalysts from expanding polyurethane production facilities. Manufacturers across industries such as construction, automotive, and electronics are increasing polyurethane output to meet rising global demand. 

This expansion requires highly efficient catalysts to accelerate reaction times and ensure consistent product quality. Catalysts act as an important component in optimizing the curing process and enabling precise control over foam structure, density, and performance. 

With the scale-up of production, particularly in flexible and rigid foam applications, the demand for advanced catalyst systems is rising and contributing to sustained market expansion.

• In April 2025, Dongsung Chemical inaugurated its new polyurethane (PU) production facility in Indonesia. The plant spans 81,000 square meters and has a yearly production capacity of 67,000 tons of polyester polyols, prepolymers, and polyurethane resins. The facility triples the company’s PU output compared to its existing plants in Vietnam, Korea, and China, and is expected to generate approximately USD 150 million in annual revenue.

Market Challenge

Health and Safety Concerns Related to Toxicity of Certain Catalyst Types

The polyurethane catalyst market faces a major challenge due to health and safety concerns related to the toxicity of certain amine and organometallic catalysts. These materials can release harmful emissions during manufacturing and use, raising risks for workers and end-users. 

Regulatory authorities and customers are increasing pressure on manufacturers to limit exposure and ensure safer formulations. This is affecting demand in applications such as consumer goods and flexible foam.

To address this challenge, companies are focusing on developing low-emission and non-toxic alternatives. They are also improving workplace safety practices and investing in research to develop catalysts that meet both performance and safety requirements.

Market Trend

Widespread Adoption of Polyurethane Systems for Battery Protection in Electric Vehicles

The market is witnessing a notable shift toward the increasing adoption of polyurethane systems for electric vehicle battery protection. Electric vehicle production is rising across key markets, and manufacturers are focusing on materials that offer both thermal insulation and fire resistance to ensure battery safety and longevity. 

Polyurethane systems provide these properties while maintaining a lightweight structure, which is essential for improving vehicle efficiency. This is creating a strong demand for catalysts that enable the formulation of high-performance polyurethane materials suitable for battery enclosures and thermal barriers. 

As electric mobility continues to expand, manufacturers are responding with specialized catalyst solutions that meet the technical requirements of EV applications.

• In April 2024, Huntsman launched its new SHOKLESS polyurethane systems designed to protect electric vehicle (EV) batteries. These lightweight, durable foam technologies support the potting and fixation of cells in EV battery packs and can function as moldable encapsulants. The SHOKLESS systems offer structural and thermal protection at cell, module, or pack levels, with broad processing flexibility and fast cure times.

Polyurethane Catalyst Market Report Snapshot

Segmentation	Details
By Product Type	Amine Catalysts, Metal / Organometallic, Bismuth & Other Catalysts, Other Specialty Types
By Function	Gelling Catalysts, Blowing Catalysts, Curing Catalysts, Foam Stabilizers, Cross-linking Catalysts, Others
By Application	Flexible Foam, Rigid Foam, Coatings, Adhesives & Sealants, Elastomers, Others
By Region	North America: U.S., Canada, Mexico
	Europe: France, UK, Spain, Germany, Italy, Russia, Rest of Europe
	Asia-Pacific: China, Japan, India, Australia, ASEAN, South Korea, Rest of Asia-Pacific
	Middle East & Africa: Turkey, U.A.E., Saudi Arabia, South Africa, Rest of Middle East & Africa
	South America: Brazil, Argentina, Rest of South America

Market Segmentation

• By Product Type (Amine Catalysts, Metal / Organometallic, Bismuth & Other Catalysts, and Other Specialty Types): The amine catalysts segment earned USD 727.4 million in 2024 due to their high efficiency in controlling reaction rates and compatibility with a wide range of polyurethane formulations.
• By Function (Gelling Catalysts, Blowing Catalysts, Curing Catalysts, Foam Stabilizers, Cross-linking Catalysts, and Others): The gelling catalysts segment held a share of 30.00% in 2024, attributed to their critical role in defining the cell structure and mechanical strength of polyurethane foams.
• By Application (Flexible Foam, Rigid Foam, Coatings, Adhesives & Sealants, Elastomers, and Others): The flexible foam segment is projected to reach USD 1,694.0 million by 2032, owing to rising demand for bedding, furniture, and automotive cushioning applications.

Polyurethane Catalyst Market Regional Analysis

Based on region, the global market has been classified into North America, Europe, Asia Pacific, Middle East & Africa, and South America.

The North America polyurethane catalyst market share stood at 34.15% in 2024, valued at USD 868.5 million. This dominance is reinforced by the strong presence of established polyurethane foam manufacturers serving the automotive and construction sectors, which create a consistent demand for durable, energy-efficient materials that rely on flexible and rigid polyurethane foams. 

Manufacturers in the region prioritize performance, quality, and regulatory compliance, promoting the use of advanced catalyst systems. Additionally, ongoing investments in infrastructure renovation and electric vehicle production lead to the steady consumption of polyurethane catalysts.

The Asia-Pacific polyurethane catalyst industry is poised to grow at a CAGR of 6.89% over the forecast period. This growth is Fostered by the rapid expansion of polyurethane production capacities across emerging economies such as China, India, and Southeast Asia. This expansion is supported by rising demand for consumer goods, insulation materials, and automotive components. 

Manufacturers are increasing output to meet both domestic and export requirements, highlighting the rising need for reliable and efficient catalyst systems. Government support for industrial development and investment in manufacturing facilities is further accelerating catalyst use in the region.

• In July 2024, Sansera Engineering Limited signed a memorandum of understanding with the government of Karnataka to invest USD 251 million in a new manufacturing facility in Ramanagara. The investment aims to expand production capacity in the automotive and non-automotive sectors over the next three to five years.

Regulatory Frameworks

• In the U.S., polyurethane catalysts are regulated under the Toxic Substances Control Act (TSCA), which requires manufacturers to report and evaluate chemical substances before they are introduced into commerce.
• In Europe, polyurethane catalysts fall under the REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) regulation, which mandates detailed safety data and risk assessments for all chemical substances used in manufacturing.
• In Japan, regulation is managed under the Chemical Substances Control Law (CSCL), which classifies and monitors chemicals based on their risk to human health and the environment.

Competitive Landscape

Key players in the polyurethane catalyst market are focusing on product innovation and regional expansion to strengthen their competitive position. Companies are actively investing in research and development to create advanced catalyst formulations that improve processing efficiency and reduce environmental impact, as demand rises for low-emission and application-specific polyurethane systems. 

Furthermore, manufacturers are expanding operations in high-growth regions such as Asia Pacific to meet rising local demand and reduce supply chain dependencies. By establishing regional production facilities and distribution channels, they are improving delivery capabilities and increasing responsiveness to market needs.

List of Key Companies in Polyurethane Catalyst Market:

• Huntsman International LLC
• BASF
• Shepherd Chemical
• Gulbrandsen
• Tandy Innavative Chemicals
• Elé Corporation
• Everchem Specialty Chemicals
• Reaxis Inc.
• San-Apro Ltd.
• Milliken & Company
• PATCHAM
• TIB Chemicals AG
• DURA Chemicals, Inc.
• UMICORE NV
• LANXESS

Recent Developments (Expansion)

• In August 2023, Gulbrandsen commissioned its new tin catalyst production plant at its Dahej site in India. The facility will manufacture stannous neodecanoate and stannous octoate to meet rising demand and strengthen its supply capabilities in the polyurethane foaming industry.