Borealis and Hosokawa Alpine Pioneer Ultra-Thin, High-Performance MDO Films for More Sustainable Packaging

Borealis and Hosokawa Alpine Pioneer Ultra-Thin, High-Performance MDO Films for More Sustainable Packaging

(IN BRIEF) Borealis and Hosokawa Alpine have successfully developed MDO films using BorShape™ polyethylene that are thinner than industry norms—just 15 microns compared to the standard 23—without compromising mechanical strength or process stability. Tested in early 2025, these films offer improved optics and performance while supporting monomaterial, recyclable packaging solutions. The collaboration highlights Borealis’ commitment to circularity and opens new doors for resource-efficient, sustainable flexible packaging.

(PRESS RELEASE) VIENNA, 24-Apr-2025 — /EuropaWire/ — Borealis, a global leader in advanced and circular polyolefin solutions, has once again demonstrated the power of collaboration through an innovation-driven partnership with long-time ally Hosokawa Alpine. Together, the companies have successfully pushed the boundaries of Machine Direction Orientation (MDO) film technology by developing thinner, high-quality polyethylene (PE) film structures that retain strength and performance while supporting sustainability goals.

The collaboration focused on testing Borealis’ BorShape™ PE materials at Hosokawa Alpine’s state-of-the-art test center. BorShape, designed with proprietary Borealis technology, offers excellent thermal resistance, low gel levels, reliable processability, and high mechanical strength. These attributes make it ideal for creating monomaterial structures that are easier to recycle.

One key goal of the trials was to explore how far MDO film thickness could be reduced without sacrificing process stability or quality. The tests delivered groundbreaking results: the team successfully produced films as thin as 15 microns—significantly below the standard 23 microns—while maintaining excellent optics, process stability, and mechanical properties. Even at a stretching ratio close to 7, the process remained consistent, underscoring BorShape’s robust performance.

Trials conducted at Borealis’ Innovation Headquarters in Linz in January 2025 confirmed the promising outcomes. Thinner MDO films not only held their mechanical strength but also displayed improved optical qualities, reinforcing their potential for high-performance monomaterial packaging.

Peter Voortmans, Vice President Marketing Consumer Products at Borealis, emphasized the importance of the results: “This is a great example of how innovation can drive sustainable transformation in flexible packaging. BorShape enables thinner, recyclable film structures that reduce material use while retaining quality.”

The achievement aligns with Borealis’ commitment to circularity and its ambition to design packaging solutions that are resource-efficient and easier to recycle. The success of the tests also paves the way for joint customer development efforts to implement BorShape in commercial packaging applications.

Bernd Bayer, Head of R&D at Hosokawa Alpine, added: “Having Borealis in our test center enabled us to truly explore the limits of what MDO technology can deliver. These results point to a future of thinner, more efficient, and environmentally friendly packaging.”

Media Contact:

Tel: +43 1 22 400 899
email: media@borealisgroup.com

SOURCE: BOREALIS