Borealis Expands Next-Generation Polypropylene Capacity to Support Circular Material Solutions

Photo: Borealis invests EUR 49 million in its production location Burghausen, to accelerate commercial scale-up of Borstar® Nextension polypropylene technology. © Borealis

(IN BRIEF) Borealis is investing €49 million to scale up commercial production of Borstar® Nextension polypropylene at its Burghausen site in Germany, expanding access to next-generation single-site PP materials. The investment supports the transition to high-performance monomaterials that enable circular design, improved recyclability, and enhanced material performance across applications such as packaging, healthcare, mobility, and fibers. By increasing production capacity, Borealis aims to help customers meet evolving regulatory requirements, including EU recyclability targets, while advancing sustainable material innovation.

(PRESS RELEASE) VIENNA, 20-Jan-2026 — /EuropaWire/ — Borealis has announced a €49 million strategic investment to accelerate the commercial scale-up of its Borstar® Nextension polypropylene technology at the company’s manufacturing site in Burghausen, Germany. The investment will expand production of next-generation single-site polypropylene grades, strengthening Borealis’ ability to supply high-performance materials that offer enhanced purity, improved processability, and advanced performance characteristics.

The expanded production capacity is designed to support customers across key industries including packaging, healthcare, mobility, and fibers as they respond to increasingly stringent market and regulatory requirements. By increasing the availability of Borstar Nextension polypropylene, Borealis aims to help customers adopt innovative material solutions that combine technical excellence with sustainability-driven design.

A central focus of the investment is enabling the shift toward high-performance monomaterial polypropylene solutions. Borstar Nextension technology integrates a tailored set of performance properties into a single PP material, allowing complex multilayer structures to be replaced with monomaterials. This supports design for circularity by reducing material complexity, lowering weight, and improving overall functional performance.

Photo: Borstar Nextension PP technology enables the transition to high-performance and recyclable monomaterials supporting design for circularity © Borealis

In packaging applications, Borstar Nextension polypropylene plays a critical role in meeting recyclability targets set out in the EU Packaging and Packaging Waste Regulation, including the objective of achieving fully recyclable packaging by 2030. The growing portfolio of Borstar Nextension grades is already being applied in flexible packaging, where it delivers improved processability alongside higher purity, clarity, and sealing performance.

Through this investment, Borealis is reinforcing its commitment to advancing circular economy solutions and supporting customer growth. By scaling up production of Borstar Nextension polypropylene, the company is expanding access to innovative, recyclable polymer materials that help customers remain competitive while addressing sustainability and regulatory challenges across multiple end markets.

About Borealis
Borealis is one of the world’s leading providers of advanced and sustainable polyolefin solutions. In Europe, Borealis is also an innovative leader in polyolefins recycling and a major producer of base chemicals. We leverage our polymer expertise and decades of experience to offer value-adding, innovative and circular material solutions for key industries such as consumer products, energy, healthcare, infrastructure and mobility.

With customers in over 120 countries and head office in Vienna, Austria, Borealis employs around 6,200 people. In 2024, we generated a net profit of EUR 566 million. OMV, the sustainable chemicals, fuels and energy company with a focus on circular economy solutions, headquartered in Vienna, Austria, owns 75% of our shares. The Abu Dhabi National Oil Company (ADNOC), based in the United Arab Emirates (UAE), owns the remaining 25%.

In re-inventing essentials for sustainable living, we build on our commitment to safety, our people, innovation and technology, and performance excellence. We are accelerating the transformation to a circular economy of polyolefins and expanding our geographical footprint to better serve our customers around the globe. Our operations are augmented by two important joint ventures: Borouge (with ADNOC, headquartered in the UAE); and Baystar™ (with TotalEnergies, based in the US).
www.borealisgroup.com | www.borealiseverminds.com

Media Contacts:

Group Media Desk
+43 1 22 400 899 (Vienna, Austria)
media@borealisgroup.com

SOURCE: BOREALIS