Borealis, a global leader in advanced and sustainable polyolefin solutions, is taking a major step forward in its circular economy journey with a substantial investment of more than EUR 100 million in its production facility located in Burghausen, Germany. This strategic move will support the construction of a new, state-of-the-art production line dedicated to the manufacturing of Daploy™, an innovative and fully recyclable High Melt Strength polypropylene (HMS PP) foam material. The new production line is scheduled to come online in the second half of 2026 and is expected to triple the company’s current capacity to supply this material.

The development and introduction of Daploy™ were led by the Borealis Innovation Center in Linz, Austria. This next-generation material was engineered to meet the growing demand for more sustainable, high-performance solutions across a range of industries. Daploy™ offers a unique combination of lightweight structure and robust mechanical strength, all within a mono-material design. This composition makes it easier to recycle and enhances material circularity, helping manufacturers meet sustainability targets by reducing waste and carbon emissions.

Daploy™ is already proving to be a game-changer in industries such as automotive, construction, and advanced consumer goods, where manufacturers are seeking high-performance alternatives to conventional multi-material foams. The use of a single-material system simplifies recycling processes and supports eco-design principles, a growing focus for companies striving to comply with environmental regulations and consumer expectations for greener products.

The investment also supports Borealis’ “We4Customers” strategy, which emphasizes collaboration and innovation to provide customers with the materials and support needed to create the next generation of sustainable products. With this expansion, Borealis continues to leverage its deep expertise in specialty polypropylene, underscoring its dedication to responsible growth and its leadership in circular innovation.

“As an innovation and sustainability leader with over 12,000 patents, we are proud to expand our European manufacturing footprint with this exciting new production capability,” said Borealis CEO Stefan Doboczky. “Through our We4Customers strategy, we are not just supplying materials — we are enabling our partners to design and deliver high-performance, recyclable products that support a more sustainable future.”

The Burghausen expansion reflects Borealis’ broader commitment to investing in cutting-edge R&D and production infrastructure across Europe. By scaling up Daploy™ production, Borealis is helping accelerate the shift toward a more circular and low-carbon economy while supporting customers in key industries with advanced, recyclable solutions.

This investment reinforces Borealis’ position as a pioneer in sustainable materials and innovation, driving real change in how materials are produced, used, and recycled throughout the value chain.