Borealis globally deploys AI-driven Borstar Digital Twin, boosting efficiency, safety, sustainability, and customer value across all Borstar production units.
Borealis has announced the global rollout of its advanced Borstar® Digital Twin program, setting a new benchmark for the use of artificial intelligence and digitalization in industrial operations. This initiative reflects Borealis’ continued commitment to pushing the limits of digital innovation by embedding AI-driven intelligence directly into core production processes. The worldwide deployment of the Borstar Digital Twin represents a major step forward in transforming how manufacturing plants operate, make decisions, and continuously improve performance.
At its core, the Borstar Digital Twin is a sophisticated suite of digital solutions that merges cutting-edge technology with Borealis’ deep expertise in process engineering. By combining artificial intelligence, real-time optimization tools, and advanced data analytics, the platform delivers a highly accurate virtual representation of the physical production process. This digital replica allows plants to monitor operations in real time, anticipate future process behavior, and run advanced simulations without disrupting actual production. As a result, Borealis facilities can achieve new levels of efficiency, productivity, and operational reliability.
The capabilities of the Borstar Digital Twin extend across multiple dimensions of plant performance. It supports data-driven decision-making by enabling operators and engineers to optimize processes using predictive insights and scenario-based simulations. Safety is enhanced through early identification and prediction of potential process or equipment issues, allowing preventive action before problems escalate. Sustainability objectives are also strengthened, as the system helps reduce waste, lower energy consumption, and minimize overall environmental impact. In addition, the platform accelerates innovation by shortening product development cycles and enabling virtual operator training in a risk-free digital environment.
The Borstar Digital Twin program was initially launched in 2023, with a specific focus on Borealis’ proprietary Borstar® technology used in the production of polyethylene and polypropylene. From the outset, the program was designed to ensure that production plants operate at peak efficiency while maintaining consistently high product quality. By 2025, Borealis reached a digital maturity milestone that made it possible to scale this solution globally. The program is now being rolled out across all Borstar units worldwide, including those operated by licensees such as Baystar™ and Borouge. This global expansion signals a new phase in which digital tools and AI-enabled workflows are becoming standard practice within Borealis’ core manufacturing operations.
According to Wolfram Krenn, Executive Vice President Operations at Borealis, the adoption of the Borstar Digital Twin goes far beyond simply introducing new technology. He explains that by integrating AI-based predictions with rigorous process models, plants can operate more efficiently, execute faster and more controlled grade transitions, and consistently deliver prime-quality products. Real-time monitoring also enables early detection and mitigation of process deviations or equipment anomalies, reducing unplanned shutdowns and improving overall reliability.
From a strategic perspective, Borealis CEO Stefan Doboczky highlights the broader value of the initiative. He emphasizes that the Borstar Digital Twin transforms advanced technology into a tangible customer benefit by delivering greater speed, reliability, and quality. In doing so, the program directly supports Borealis’ We4Customers strategy, reinforcing the company’s focus on customer success while strengthening its competitive position in the global polymers market.
