Borealis is investing over €100 million into a new High Melt Strength polypropylene line, aiming to triple its capacity and address global demand for reusable cups, food packaging, and other recyclable, lightweight polymer foam solutions.
Scheduled to launch at its Burghausen facility in the second half of 2026, the new line focuses on Borealis’ Daploy High Melt Strength polypropylene foam solution, which is designed for foamability, mechanical strength, and lightweight properties.
Apparently, these characteristics bolster material efficiency while reducing CO2 emissions and manufacturing costs. Its suitability for mono-material solutions is also expected to bolster end-of-life recyclability for its end applications.
As such, Borealis recommends its use in the production of various consumer products, including food packaging and reusable coffee cups. Daploy’s reported recyclability, light weight, and compatibility with reuse are anticipated to help brands align with the upcoming Packaging and Packaging Waste Regulation.
Additionally, the new line is expected to offer a recyclable solution for the automotive, building, and construction industries.
“In line with our We4Customers strategy, this investment creates value for customers by enabling them to design recyclable, foam-based products for a wide range of high-performance applications,” says Craig Arnold, executive vice president for Polyolefins, Circular Economy Solutions and Base Chemicals at Borealis.
“By expanding production, we’re ensuring a reliable supply of this advanced material to help our customers achieve their sustainability goals and deliver high-performance solutions.”
Visitors to K 2025 are invited to Borealis and Borouge’s stand (Hall 6, Stand A43) to view an array of Daploy HMS PP solutions and discuss how its grades could suit their performance and sustainability goals.
At the same event, a deposit-free reuse system will distribute cups manufactured by Borealis from modified polypropylene for foam, utilizing chemically recycled feedstock from OMV’s ReOil technology. According to Borealis, its cups are material-efficient and lightweight, and fully recyclable at end-of-life.
In similar news, TotalEnergies Corbion and Useon have joined forces to drive the development and commercialization of EPLA moulded products, or high-performance foam materials made from Luminy PLA bioplastics. EPLA foam products are described as lightweight, protective and durable, making them suitable for packaging, food service, and cold-chain applications.
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