Responding to a Market Shift
Demand for recyclable lightweight foam solutions with strong mechanical strength is rising across Europe. To address this shift, Borealis is tripling its High Melt Strength polypropylene (HMS PP) production capacity in Burghausen, Germany. The investment strengthens supply reliability while introducing new technology for fully recyclable HMS PP.
The expansion supports customers that require materials combining performance, durability, and circularity. By increasing local production, Borealis positions the site as a strategic hub for next-generation polyolefin solutions.
Advancing Circular Material Solutions
At the centre of this expansion is HMS PP, a material designed to meet strict sustainability and performance requirements. It aligns with the principles of Reduce, Reuse, and Recycle, offering manufacturers a practical pathway toward circular product design.
The material’s high melt strength enables lightweight foamed structures without compromising mechanical performance. It also supports recyclability at both production and end-of-life stages.
Craig Arnold, Executive Vice President Polyolefins, Circular Economy Solutions and Base Chemicals at Borealis, explains:
In line with our 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 are ensuring a reliable supply of this advanced material to help our customers achieve their sustainability goals and deliver high-performance solutions.
Consumer Products: Meeting Regulatory Pressure
Regulatory frameworks such as the EU Packaging and Packaging Waste Regulation are reshaping packaging design requirements. HMS PP offers a lightweight and recyclable option for reusable coffee cups and food packaging applications.
Its durability supports repeated use, while its recyclability helps producers comply with evolving European standards. The material enables packaging manufacturers to reduce material usage without sacrificing performance.
Automotive: Driving Efficiency Through Lightweighting
Weight reduction remains a critical lever for lowering emissions and improving fuel efficiency. In automotive interiors and under-the-hood components, HMS PP enables ultra-lightweight foamed parts that are typically 60 to 90 percent lighter than non-foamed alternatives.
The material also supports zero-waste production. Trim-offs generated during manufacturing can be recycled directly back into the process. In addition, single-material construction simplifies recycling at vehicle end-of-life, improving material recovery rates.
Building and Construction: Stronger, Lighter Solutions
In building and construction, HMS PP replaces heavier materials in insulation and panelling applications. Its strength, durability, and heat resistance ensure long-term performance in demanding environments.
At the same time, its lightweight nature reduces transportation impact and simplifies installation. Recyclability further enhances the sustainability profile of construction components.
Securing Supply for the Future
The Burghausen expansion will be fully operational in the second half of 2026.. The additional capacity ensures stable supply for customers across consumer products, automotive, and construction industries.
By investing in advanced recyclable materials, Borealis strengthens its commitment to circular economy solutions while enabling customers to design lighter, high-performance products built for a more sustainable future.