Borealis is committed to fostering growth through sustainable solutions that are revolutionizing the polymer sector. Its facility in Burghausen, Germany, is significantly boosting production capacity for an innovative polymer foam solution known as Daploy™ High Melt Strength polypropylene (HMS PP).

Source: BorealisGroup

This investment, exceeding EUR 100 million, aims to meet the rising global demand for recyclable, high-performance foam materials. The new production line, set to commence in the latter half of 2026, will triple Borealis’ capability to supply fully recyclable HMS PP. This expansion supports the shift towards more circular and recyclable material solutions for customers across the consumer products, automotive, and building and construction industries.

The creation of Daploy HMS PP occurred at Borealis’ Innovation Headquarters in Linz. This innovative product boasts exceptional foamability, lightweight characteristics, and mechanical strength—qualities that enhance material efficiency while reducing both costs and CO2 emissions. It is also suitable for monomaterial solutions, which are easily recyclable at the end of their lifecycle.

By adhering to the sustainability principles of Reduce, Reuse, and Recycle, Daploy HMS PP meets the increasing demand for recyclable solutions across various industry sectors:

• Consumer Products: Daploy HMS PP is perfect for a variety of applications, including reusable coffee cups and food packaging. As a lightweight and recyclable material, it assists packaging manufacturers in complying with the EU Packaging and Packaging Waste Regulation (PPWR).
• Automotive Industry: Daploy is utilized for ultra-lightweight foamed interior components and under-the-hood parts. Typically 60-90% lighter than non-foamed alternatives, these components enhance fuel efficiency and help lower carbon emissions. Additionally, it promotes zero-waste production since all production trim-offs can be readily recycled. Furthermore, Daploy allows these parts to be made from a single material, simplifying recycling at the end of the vehicle's life.
• Building and Construction Sector: Daploy HMS PP is employed to replace heavier materials in insulation and paneling applications. Its durability, strength, and heat resistance ensure exceptional performance, while its lightweight and recyclable nature boosts the sustainability of these components.

This expansion exemplifies Borealis' commitment to delivering innovative, high-quality products that promote sustainability and reinforces its leadership within the polypropylene 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. 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.

^{Craig Arnold, Borealis Executive Vice President Polyolefins, Circular Economy Solutions and Base Chemicals}

Visitors attending K 2025 will have the chance to explore a variety of Daploy HMS PP solutions at the Borealis and Borouge stand in Hall 6, Stand A43, and discuss how these grades can assist them in achieving their sustainability and performance objectives.