A deep dive into the scale, complexity, and business metrics driving the US chemical sector.
A deep dive into the scale, complexity, and business metrics driving the US chemical sector.
The US chemical industry accounts for over $800 billion in annual revenue and supports more than 25% of the US GDP. From plastics to pharmaceuticals, it is the cornerstone of sectors that touch nearly every facet of daily life. However, the scale and complexity of this industry are not just about large numbers—they’re about efficiency, innovation, and resilience in a fast-evolving global market.
Take carbon black for instance, —a crucial reinforcing agent that comprises about 30% of every tire on the road today. This fine, powdered form of carbon gives tires their characteristic black color and provides essential durability and wear resistance, demonstrating how a single chemical ingredient can be fundamental to modern transportation safety and performance. Similarly, titanium dioxide (TiO2), found in everything from the paint on your walls to the sunscreen on your skin, represents another multi-billion-dollar market that showcases how chemical manufacturing silently underpins modern living standards.
In this blog, we break down the nature of the US chemical business and highlight the critical metrics that shape its impact. Whether you’re tracking capacity utilization or navigating fluctuating raw material costs, understanding these key performance indicators is essential for success. This detailed look at the industry’s foundation will give you the insights needed to navigate its challenges and opportunities.
The nature of the landscape
The US chemical industry is marked by large-scale, capital-intensive operations, relying on vast amounts of raw materials like oil, gas, and minerals. These inputs drive high-volume production lines, often running continuously to maximize efficiency. Advanced technology ensures minimal downtime and compliance with strict regulations while meeting global demand. Dow Inc., the largest US-based chemical manufacturer, operates over 100 production sites worldwide, with a production capacity exceeding 30 million metric tons annually. This scale highlights the industry's focus on optimizing both capacity and sustainability.
1. Capital-intensive operations
Chemical plants represent some of the most capital-intensive facilities in the industrial sector, with the industry's capital spending reaching $27.8 billion in 2021 alone. The scale is staggering—a single world-scale petrochemical plant requires a fixed capital investment ranging from $1 billion to $10 billion. This is exemplified by ExxonMobil and SABIC's Gulf Coast Growth Ventures project, a $7 billion petrochemical complex in Texas that began operations in 2022. Once built, these facilities are expected to run with high efficiency for years, if not decades. This scale of operation requires a constant and reliable supply of raw materials, making the entire upstream supply chain critical to the ongoing success of the business. The upstream reliance, primarily on the oil and gas industry, introduces volatility, especially given the fluctuating nature of commodity prices.
2. Continuous production cycles
Most chemical production operates on continuous cycles, maintaining an impressive industry-wide capacity utilization rate of 75-80%. These continuous processing methods can improve productivity by 30-40% compared to batch processing, as demonstrated by industry leaders like Dow Chemical Company, which operates its ethylene and polyethylene facilities 24/7, stopping only for planned maintenance. These operations are rarely halted because any downtime can result in massive financial losses, given the volume of output expected. Continuous production also adds complexity to the supply chain—companies need to maintain an uninterrupted supply of raw materials while ensuring that finished products are distributed efficiently to downstream customers across the globe.
3. Industry diversification and market demand
The chemical industry's reach is vast, with $516 billion in chemical shipments in 2021 alone. Specialty chemicals, accounting for 28% of total chemical shipments, demonstrate the industry's adaptability to specific market needs. Companies like DuPont exemplify this diversification, having evolved their portfolio to include advanced materials for electronics, water purification solutions, and specialized polymers. The products of the US chemical industry are integral to numerous other sectors, meaning that its output drives innovation and growth in industries like pharmaceuticals, automotive, agriculture, and technology. For instance, the rise in electric vehicle production has surged demand for chemical inputs such as battery components.
4. Regulatory landscape
With over 86,000 chemicals registered under the Toxic Substances Control Act (TSCA), the chemical industry faces one of the most complex regulatory environments in manufacturing. Industry commitment to compliance is reflected in the $14.5 billion spent by American Chemistry Council members on environmental, health, safety, and security programs in 2021. Global regulations, such as the EU's REACH requirements, have pushed US manufacturers to adapt their practices and product formulations to maintain access to international markets. These regulations influence everything from emissions and waste management to product safety and transportation, requiring companies to constantly innovate while managing compliance costs.
Business impact metrics
Given the nature of the chemical business, several key performance indicators (KPIs) and metrics determine its financial and operational success. These metrics are essential for evaluating performance across the supply chain, from raw material procurement to production efficiency and delivery logistics.
-
Capacity utilization rate: In a capital-heavy industry like chemicals, capacity utilization is a vital metric that reflects how well companies maximize their production assets. With the average capacity utilization rate for the US chemical industry at 77.7% in 2022, operating at near full capacity is essential for profitability. A 1% increase in capacity utilization can lead to a 2.5-3% rise in EBIT, underscoring its direct impact on financial performance. For instance, LyondellBasell, one of the major chemical manufacturers, reported an impressive 85% capacity utilization rate for their olefins and polyolefins segments in North America in 2022. Any drop in this metric can lead to higher per-unit costs and lost revenue opportunities, making it a key area of focus for operational optimization.
-
Energy efficiency: Energy consumption represents one of the most significant cost components in chemical manufacturing, often accounting for 5-7% of total production costs. Improving energy efficiency not only cuts costs but also reduces environmental impact, a growing concern in today’s regulatory environment. The US chemical industry has made strides in this area, improving energy efficiency by 19% since 2001, as reported by the American Chemistry Council. Companies like Dow Chemical are leading by example, to reduce their net annual energy intensity by 15% between 2015 and 2025. Such initiatives not only reduce operational costs but also align with broader sustainability goals, enhancing both financial performance and corporate responsibility.
-
Raw material efficiency: The effective use of raw materials is another crucial factor in maintaining profitability. Raw material costs, particularly for oil, gas, and minerals, are highly volatile and have a direct impact on margins. According to the American Chemistry Council, the US chemical industry has improved its raw material efficiency by 7% since 2001. Even a slight 1% increase in raw material yield can translate into a 2-3% boost in EBIT, making raw material efficiency a high priority for companies. BASF, for instance, has achieved a 94% raw material efficiency in their Verbund production system, showcasing how optimization in this area can significantly affect overall performance.
-
Inventory turnover ratio: Inventory management plays a crucial role in the chemical industry due to the high cost of holding large amounts of raw materials and finished goods. The inventory turnover ratio is a key metric that indicates how quickly companies can sell and replace their inventory. In 2022, the average inventory turnover ratio for the US chemical industry was 5.2, reflecting a healthy balance between inventory levels and sales. A higher ratio typically indicates greater efficiency and a 0.5-1% improvement can boost ROA (Return on Assets). Companies like DuPont de Nemours, with a turnover ratio of 4.3 in 2022, highlight the continuous need for improvement in inventory management to remain competitive.
-
On-time in-full (OTIF) delivery rate: In the chemical industry, timely and complete delivery of products is crucial for maintaining customer satisfaction and minimizing supply chain disruptions. The OTIF delivery rate measures the percentage of orders delivered on time and in full. The industry average ranges between 85-90%, and even a 1% improvement in OTIF can enhance customer retention rates by 0.5-1%. This metric is not just about operational efficiency—it directly impacts customer loyalty and revenue. Eastman Chemical Company, for example, achieved an OTIF rate of 96% in 2021, setting a high standard in the industry. Improving OTIF is often tied to better logistics planning and supply chain coordination.
-
Return on capital employed (ROCE): ROCE is one of the most telling financial metrics, as it measures how efficiently a company uses capital to generate profits. In the US chemical industry, the average ROCE stood at 14.2% in 2022. However, top-performing companies in the sector reach ROCE levels of 20% or higher, as indicated by McKinsey’s analysis of the chemical industry's financial performance. This metric is critical for understanding long-term financial health and competitiveness. For example, Air Products and Chemicals, Inc. reported a ROCE of 10.9% in fiscal 2022, highlighting areas where capital efficiency could be improved relative to industry leaders. High ROCE reflects a company's ability to generate strong returns from its investments, positioning it for sustainable growth.
What lies ahead: Navigating the future of chemical supply chains
The US chemical industry’s supply chain is a uniquely complex and vital, balancing regulatory demands, cost volatility, and high-volume production. Its ability to maintain efficiency while driving innovation makes it a linchpin of the US economy and a leader in global markets.
In Part 2, we’ll dive into the emerging trends reshaping this critical sector. From AI-driven logistics to sustainability innovations, find out how top companies are evolving to meet the demands of a fast-changing world. Stay tuned for insights into the future of chemical supply chains!
