Borealis is investing 100 million euros to triple its PP foam production

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). This investment – totalling over 100 million euros – 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.

The 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. Daploy HMS PP addresses the growing demand for recyclable solutions across multiple industry segments:
- its properties 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);
- in the automotive industry, it 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, it makes it possible for these parts to be constructed from a single material, facilitating recycling at the end of the vehicle’s life;
- in the building and construction sector, it is used to replace heavier materials in insulation and panelling applications; its durability, strength, and heat resistance ensure excellent performance, while its lightweight properties and recyclability improve the sustainability of these components.

“In line with our We4Customers strategy, this investment creates value for customers by enabling them to design recyclable, foam-based products for a wide range of high-performance applications,” explained Craig Arnold, Borealis Executive Vice President Polyolefins, Circular Economy Solutions and Base Chemicals. “By expanding production, we’re ensuring a reliable supply of this advanced material to help our customers achieve their sustainability goals and deliver high-performance solutions.”