Borealis Expands Capacity for HMS-PP

• Borealis invests over €100 million in new Daploy high melt strength polypropylene (HMS-PP) line at its Burghausen, Germany, facility. Start-up is planned for the second half of 2026.

• Borealis Innovation Headquarters in Linz, Austria, spearheaded breakthrough innovation in design for recycling with Daploy

• The new line will triple Borealis’ supply capability for HMS-PP that enables high-performance and light weight foam solutions.

• MLT Analytics published a detailed report on HMS-PP in 2023.

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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). Borealis uses a post-reactor cross linking process to produce HMS-PP.

This investment—totaling over €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. This expansion enables the transition to more circular and recyclable material solutions for customers in the consumer products, automotive, and building and construction industries.

Development of Daploy HMS-PP took place at Borealis’ Innovation Headquarters in Linz. 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:

• 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.

  
  

  

  With Daploy HMS polypropylene we enable automotive foam ducts that are lighter, have better thermal and acoustic insulation and are designed for recycling. Image courtesy of Borealis

  
  

• 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.

• 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).

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