Borealis is making a major stride in sustainable innovation with a significant investment in its polymer foam capabilities. The company has announced a more than EUR 100 million investment to expand production of its proprietary Daploy™ High Melt Strength polypropylene (HMS PP) at its Burghausen, Germany, facility. This expansion will triple Borealis’ capacity to supply this fully recyclable, lightweight polymer foam solution, with the new line scheduled to be operational in the second half of 2026.

This bold move is in response to the rising global demand for sustainable, high-performance materials across key sectors such as consumer goods, automotive, and construction. With the expanded production, Borealis aims to accelerate the industry’s transition toward more circular, recyclable material solutions that align with evolving regulatory and environmental expectations.

Daploy HMS PP, developed at Borealis’ Innovation Headquarters in Linz, Austria, is engineered for outstanding foamability, superior mechanical strength, and low weight. These properties not only enhance material efficiency but also reduce costs and carbon emissions. Unlike multi-material alternatives, Daploy enables monomaterial applications that are easier to recycle at the end of their lifecycle, making it ideal for a circular economy.

The product supports the core sustainability principles of Reduce, Reuse, and Recycle, and its application potential is vast. In the consumer products industry, Daploy HMS PP is already being used to manufacture items such as reusable coffee cups and food packaging. These products benefit from the material’s low weight, durability, and recyclability, helping manufacturers comply with the European Union’s Packaging and Packaging Waste Regulation (PPWR).

In the automotive sector, Daploy is gaining traction for use in ultra-lightweight foamed interior and under-the-hood components. These parts are 60% to 90% lighter than traditional alternatives, improving fuel efficiency and reducing emissions. The material also enables zero-waste production, as trim-offs can be easily recycled, and parts can be constructed from a single polymer for simplified end-of-life recycling.

For the building and construction industry, Daploy HMS PP is a lightweight replacement for heavier materials in insulation and paneling applications. Its strength, heat resistance, and durability ensure excellent performance while enhancing the recyclability and overall sustainability of these components.

This expansion underscores Borealis’ continued leadership in the polypropylene market and its commitment to delivering value through sustainable innovation. “In line with our We4Customers strategy, this investment enables customers to design recyclable, foam-based products for a wide range of high-performance applications,” said Craig Arnold, executive vice president of Polyolefins, Circular Economy Solutions and Base Chemicals at Borealis. “By expanding Daploy HMS PP production, we’re ensuring a reliable supply of this advanced material to support our customers’ sustainability goals and drive meaningful industry transformation.”