Borealis invests US$113M to expand high melt strength PP production in Germany

GERMANY – Borealis, a global leader in advanced polymer solutions, has committed over €100 million (US$113.6 million) to construct a new high melt strength polypropylene (HMS PP) production line at its Burghausen facility in Germany.

The investment will triple Borealis’ capacity to supply Daploy HMS PP, an innovative and fully recyclable polymer foam material.

This expansion addresses the rising demand for sustainable, high-performance foam solutions across consumer goods, automotive, and building and construction industries. Operations are expected to begin in the second half of 2026.

Developed at Borealis’ Innovation Headquarters in Linz, Austria, Daploy HMS PP combines lightweight properties with mechanical strength, making it ideal for monomaterial applications that are easily recyclable at end of life.

It is already being used in applications such as reusable coffee cups and food packaging, aligning with the EU Packaging and Packaging Waste Regulation.

“This investment, aligned with our We4Customers strategy, enables our partners to design recyclable, foam-based products for a wide range of high-performance applications,” said Craig Arnold, Executive Vice President of Polyolefins, Circular Economy Solutions, and Base Chemicals at Borealis.

“By expanding production, we are securing a stable supply of this advanced material to help customers achieve their sustainability targets.”

In a parallel development, Borealis launched Borcycle M CWT120CL in March 2025—a new recycled linear low-density polyethylene (rLLDPE) grade tailored for flexible packaging applications.

The material contains 85% post-consumer recyclate (PCR) and 15% LLDPE booster, and is designed for blown film use in primary, secondary, and tertiary packaging, including stretch film, stretch hoods, and films for agricultural, industrial, and protective uses.

Developed in collaboration with Ecoplast, a Borealis Group member, Borcycle M CWT120CL leverages mechanical recycling technology to lower the carbon footprint of finished packaging products, supporting the transition to more sustainable packaging solutions.

Meanwhile, the company also teamed up with Finnish dairy giant Valio to introduce a new yogurt packaging solution made with recycled polypropylene (PP), aligning with the European Union’s Packaging and Packaging Waste Regulation (PPWR).

The innovation debuts with Valio’s Greek-style yogurt line, Valio Kreikkalainen Jogurtti, and integrates Borealis’ advanced Borcycle C grade in the thermoforming process to support packaging circularity.

The EU’s PPWR pushes for greater use of post-consumer recycled (PCR) content and improved recyclability across packaging.

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