Borealis Invests €100 Million to Boost Sustainable Polymer Foam Production in Germany

Borealis Invests in Sustainable Solutions

Date: 27th May 2025

Announcement

Borealis has been investing in sustainable solutions with an expectation of a transformative change in the polymer industry. Borealis is expanding its production business with its polymer foam solution ‘Daploy high melt strength polypropylene (HMS PP)’ at the company’s facility, Burghausen, Germany. The investment amount is around 100 million euros additional, with the new line. The new line is going to start up in the second half of 2026. The company initiated the Daploy HMS PP at the innovation headquarters in Linz. The Daploy HMS PP solution accelerates improvements in factors such as mechanical strength, foamability, lightweight properties, effectiveness, and efficiency in materials. It also helps in reducing CO2 emissions and costs. This ensures the availability of recyclable materials in various industries such as automotive, construction, consumer products, and building industries.

How will the solution contribute to the development of the industries?

Daploy can be used in consumer product applications, mostly in food packaging and coffee cups. The materials are recyclable and lightweight, which can be reused. This is support for the packaging producers to meet the requirements of the EU Packaging and Packaging Waste Regulation (PPWR). This solution can help the automotive industry in its under-the-hood components and ultra-lightweight foamed interior. The Daploy is 60 to 90 percent lighter in comparison to the non-foamed alternatives. This will refine fuel performance and minimize carbon emissions. It leverages zero-waste production along with production trim-offs, so it can be recycled. The contribution of this solution to the building and construction sector helps in the replacement of bulky materials in panelling and insulation applications. The solution has the potential with the strength, durability, lightweight properties, and heat resistance qualities. Hence, the recycling uplifts the sustainability levels.

Views and Statements

Borealis executive vice president, polyolefins, circular economy solutions, and base chemicals, Craig Arnold, said that according to the We4Customers strategy, the investment is increasing engagement and creating value for customers. This encourages customers to customize the design of foam-based recyclable products for high-quality performance applications. Additionally, with the expansion of production, the company is also ensuring the supply of the advanced material. This will support customers in uplifting the sustainability criteria and provide valuable solutions.

Impact

This investment is indirectly promoting the clean energy sector. The projects and investments in the sustainable journey have been a valuable approach to the packaging market. The multipurpose use of this solution in several other industries is reaching higher demands. This solution to the packaging process is an advancement. The eco-friendly approach is attracting many businesses, considering this solution.