Borealis Supercharges Circular Plastics Leadership by Expanding Borstar Nextension Polypropylene Capacity to Confront EU Sustainability and Recyclability Demands across European Industrial and Packaging Markets 21-01-2026
Borstar Nextension polypropylene
Borealis accelerates next-generation polypropylene production in Germany
Borealis has announced a €49 million strategic investment to expand commercial production of Borstar Nextension polypropylene at its Burghausen manufacturing site in Germany. The move strengthens the company’s ability to supply next-generation polypropylene materials designed to support circular economy objectives, regulatory compliance, and high-performance industrial applications.
The investment reflects growing demand for advanced polypropylene solutions that combine technical performance with recyclability. By increasing production capacity for Borstar Nextension polypropylene, Borealis aims to help customers transition toward monomaterial designs that simplify recycling while maintaining or improving functional performance.
Scaling up Borstar Nextension polypropylene for circular design
Borstar Nextension polypropylene is based on single-site catalyst technology, enabling a precise combination of mechanical strength, purity, processability, and flexibility within a single polymer grade. This technological approach allows manufacturers to replace complex multilayer structures with high-performance monomaterial polypropylene solutions.
Monomaterial design is a cornerstone of circular economy plastics. By reducing material complexity, Borstar Nextension polypropylene improves recyclability, lowers overall material usage, and supports lightweighting strategies across multiple applications. These advantages are increasingly critical as regulatory pressure and sustainability expectations rise across global markets.
Supporting EU Packaging and Packaging Waste Regulation targets
One of the key drivers behind the investment is the EU Packaging and Packaging Waste Regulation, which sets ambitious targets for recyclability and waste reduction. The regulation aims to ensure that all packaging placed on the EU market is recyclable by 2030, placing significant pressure on material choices and packaging design.
Borstar Nextension polypropylene plays a central role in helping packaging producers meet these requirements. The material is already being adopted in flexible packaging applications where it delivers improved sealing performance, higher purity, enhanced clarity, and better processability. These properties allow converters to meet both functional and regulatory demands without compromising efficiency.
Expanding applications across multiple industries
While packaging remains a major focus, the expanded production capacity at Burghausen is designed to support a broad range of industries. Borealis supplies Borstar Nextension polypropylene to customers in healthcare, mobility, fibers, and consumer goods, all of which are facing increased sustainability and compliance requirements.
In healthcare applications, material purity and consistency are critical. Single-site polypropylene offers tighter property control, supporting stringent quality standards while enabling recyclable product design. In mobility and technical applications, the material provides a balance of strength, durability, and weight reduction that aligns with energy efficiency and emissions reduction goals.
Strengthening industrial competitiveness through material innovation
By investing in Borstar Nextension polypropylene, Borealis is reinforcing its position as a technology-driven polyolefins supplier. Advanced polymer innovation allows customers to redesign products with fewer materials, lower carbon footprints, and improved end-of-life outcomes.
From an industrial competitiveness perspective, access to scalable, next-generation polypropylene materials helps manufacturers future-proof their portfolios. As sustainability criteria become embedded in procurement decisions, recyclable and circular-ready materials are increasingly a prerequisite rather than a differentiator.
Burghausen as a strategic production hub
The Burghausen site in Germany plays a strategic role in Borealis’ European production network. Expanding Borstar Nextension polypropylene capacity at a single site ensures supply reliability, consistent quality, and efficient logistics for European customers.
Single-site production also supports faster innovation cycles, enabling Borealis to scale new grades more efficiently and respond to evolving market requirements. This approach aligns with broader industry trends toward localized, resilient supply chains for critical materials.
Advancing the circular economy of polyolefins
The €49 million investment underlines Borealis’ long-term commitment to advancing the circular economy of polyolefins. Beyond production scale-up, the company continues to integrate material innovation with recyclability, design-for-recycling principles, and customer collaboration.
By expanding access to Borstar Nextension polypropylene, Borealis supports brand owners, converters, and manufacturers seeking to align commercial performance with environmental responsibility. The focus on monomaterial polypropylene solutions demonstrates how polymer innovation can act as an enabler of systemic change rather than an obstacle to sustainability.
Borealis at a glance
Borealis is one of the world’s leading providers of advanced and sustainable polyolefin solutions. In Europe, the company is also a major producer of base chemicals and a leader in polyolefins recycling. Borealis serves customers in more than 120 countries and employs approximately 6,200 people worldwide.
Headquartered in Vienna, Austria, Borealis reported a net profit of €566 million in 2024. The company is majority owned by OMV, with a 75 percent share, while the Abu Dhabi National Oil Company holds the remaining 25 percent. Borealis operates key joint ventures including Borouge with ADNOC and Baystar with TotalEnergies.
Through continuous investment in technology, people, and performance excellence, Borealis is accelerating the transformation toward sustainable living and circular material systems on a global scale.
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