Borealis invests to increase capacity for recyclable, lightweight polymer foam solutions

-Borealis invests over EUR 100 million in new High Melt Strength polypropylene (HMS PP) line at its Burghausen, Germany, facility. The start-up is planned for the second half of 2026

-Borealis Innovation Headquarters in Linz, Austria, spearheaded breakthrough innovation in design for recycling with Daploy™ High Melt Strength polypropylene (HMS PP)

-The new line will triple Borealis’ supply capability for fully recyclable HMS PP that enables high-performance and light weight foam solutions

Borealis continues to invest in growth through sustainable solutions that are transforming the polymer industry. Its facility in Burghausen, Germany, is significantly expanding production capacity for an innovative polymer foam solution called Daploy™ High Melt Strength polypropylene (HMS PP). This investment—totaling over EUR 100 million—addresses growing global demand for recyclable, high-performance foam solutions. The new line, scheduled to start up in the second half of 2026, will triple Borealis’ supply capability for fully recyclable HMS PP. This expansion enables the transition to more circular and recyclable material solutions for customers in the consumer products, automotive, and building and construction industries.

Photo: With Daploy™ HMS polypropylene we enable automotive foam ducts that are lighter, have better thermal and acoustic insulation and are designed for recycling © Borealis

The development of Daploy HMS PP took place at Borealis’ Innovation Headquarters in Linz. The new product provides exceptional foamability, lightweight properties, and mechanical strength—characteristics that support material efficiency and help cut both costs and CO2 emissions. It is suitable for use in monomaterial solutions, which are easily recyclable at end of life.

By supporting the sustainability principles of Reduce, Reuse, and Recycle, Daploy HMS PP addresses the growing demand for recyclable solutions across multiple industry segments:

The properties of Daploy HMS PP make it ideal for a wide range of consumer products applications, such as reusable coffee cups and food packaging. As a lightweight, recyclable material that supports reuse, it helps packaging producers meet the requirements of the EU Packaging and Packaging Waste Regulation (PPWR).

In the automotive industry, Daploy is used for ultra-lightweight foamed interior and under-the-hood components. Typically 60-90% lighter than non-foamed alternatives, these components help improve fuel efficiency and reduce carbon emissions. It also enables zero-waste production as all production trim-offs can be easily recycled. In addition, Daploy makes it possible for these parts to be constructed from a single material, facilitating recycling at the end of the vehicle’s life.

In the building and construction sector, Daploy HMS PP is used to replace heavier materials in insulation and paneling applications. Its durability, strength, and heat resistance ensure excellent performance, while its lightweight properties and recyclability improve the sustainability of these components.

The expansion is another example of Borealis' dedication to delivering innovative, high-quality products that advance sustainability, and reinforces its leadership in the PP market.

“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,” explains Craig Arnold, Borealis Executive Vice President Polyolefins, Circular Economy Solutions and Base Chemicals. “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 will have the opportunity to explore a range of Daploy HMS PP solutions at the Borealis and Borouge stand Hall 6, Stand A43, and discuss how these grades can help them meet their sustainability and performance goals.