High Melt Strength PP Supports Mechanical Recycling

In collaboration with Promix Solutions, Borealis has developed recyclable, lightweight packaging using Borcycle M materials with post-consumer recycled (PCR) content. The EU’s Packaging and Packaging Waste Regulation (PPWR) sets ambitious targets: by 2030, all packaging must be 100% recyclable. Additionally, non-PET packaging in contact-sensitive applications must include at least 10% recycled content, while other plastic packaging must contain 35%.

Promix's Microcell technology is a physical foaming process using eco-friendly agents (atmospheric CO₂, N₂) to reduce material density from 20% to up to 70%, depending on the application, lowering costs and carbon footprint while enhancing insulation and maintaining mechanical properties.

The partnership has yielded recyclable packaging solutions combining Borcycle M, virgin polypropylene (PP), and high melt strength (HMS) PP materials. This blend ensures excellent mechanical performance and visual quality, while meeting future PPWR requirements.

HMS-PP eliminates sheet corrugation

By adding the PCR content to the recipe there was a visible corrugation in foam sheet production. However, by incorporating additionally 10–20% HMS PP, the corrugation was removed and high stiffness—enhancing durability and structural integrity achieved.

These solutions, now in production, are ideal for non-food applications such as trays, containers, shopping baskets, and horticultural products. This collaboration showcases how innovation and partnership can accelerate circular progress in packaging.

“The integration of high-quality, mechanically recycled materials enabled by Borcycle M technology with HMS PP, represents a major step in accelerating action on circularity. Through innovation and collaboration with value chain partners such as Promix Solutions, we’re helping our customers meet regulatory demands while delivering high-performance, sustainable packaging,” says Peter Voortmans, Vice President Marketing Consumer Products at Borealis.