Borealis unveils Borstar Nextension PE platform to advance recyclable packaging

AUSTRIA – Borealis has launched its Borstar Nextension Polyethylene (PE) platform, a technology designed to enhance toughness, sealing capabilities, and processing efficiency in packaging applications. 

This development supports thinner material use, which cuts production costs and facilitates easier recycling processes.

The platform introduces mono-material options that substitute for traditional multi-layer structures, simplifying sorting and recovery at disposal facilities. 

According to company representatives, the technology processes standard PE resins through existing equipment without major modifications.

Borealis highlighted two initial materials from the platform. 

One variant offers twice the impact resistance of earlier metallocene PE grades while preserving rigidity and smooth extrusion, including stable bubble formation during blown film production. 

This makes it suitable for form-fill-seal operations and frozen food wrappers, where full recyclability remains intact. 

“Our goal is to make high-performance packaging accessible without compromising on environmental goals,” said Peter Stenmark, Borealis Executive Vice President for Polyolefins.

He added that initial tests show up to 20% higher throughput rates in pilot runs.

The second material lowers the temperature needed to start sealing by more than 15%, paired with strong adhesion during heating. 

This allows quicker line speeds and reliable bonds in laminated films and food pouches. In a statement, Borealis noted that these properties cut energy use in sealing by an estimated 10-12% per package. 

The company plans commercial availability in early 2026, with samples already distributed to select partners for validation.

Complementing this rollout, Borealis confirmed its new compounding facility for recycled polyolefins is fully active. 

The setup handles various post-consumer flakes and produces compounds meeting specifications for consumer goods, automotive parts, and energy infrastructure.

Customers can now collaborate on trials to integrate up to 50% recyclate without quality drops, according to a technical overview from the firm.

In parallel developments, NOVA Chemicals introduced PE resins using non-fluorinated processing aids last month. 

These aids match the output of older fluoropolymer versions, aiding compliance with tightening global rules on per- and polyfluoroalkyl substances. 

The resins work seamlessly with current blends to create clear films, reducing defects and enabling a shift away from restricted chemicals. 

“This transition supports our commitment to safer manufacturing,” remarked Randy G. Woelfel, NOVA’s Senior Vice President of Technology and Innovation, in a recent announcement. Early adopters report no more than 5% adjustments to extruder settings.

These innovations come amid rising demand for circular packaging solutions across Europe and North America. 

Borealis aims to scale production at its Austrian and Belgian sites, targeting a 15% share of sales from recycled-content products by year-end.

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