Investment to increase capacity for lightweight polymer foam solutions

Borealis invests over EUR 100 million in new High Melt Strength polypropylene (HMS PP) line at its Burghausen, Germany, facility. Picture: © Borealis

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.

The development of Daploy HMS PP took place at Borealis’ Innovation Headquarters in Linz. According to company, 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:

• Daploy™ HMS polypropylene helps packaging producers to meet the requirements of the EU Packaging and Packaging Waste Regulation (PPWR). © Borealis

  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.

Visitors to K 2025 will have the opportunity to explore a range of Daploy HMS PP solutions at the Borealis and Borouge stand  and discuss how these grades can help them meet their sustainability and performance goals.