Borealis announced the launch of its groundbreaking Borstar Nextension Polyethylene (PE) technology, marking a significant leap forward in polyolefin innovation. Building on the proven success of Borstar technology, this next-generation platform introduces proprietary single-site catalysts developed by Borealis to deliver a unique combination of superior performance, enhanced processability, and sustainability benefits.

The Borstar Nextension PE technology sets a new benchmark for flexible packaging solutions by enabling downgauging, improving cost efficiency, and supporting design for recycling. By making mono-material solutions possible, it allows for the replacement of multimaterial packaging, simplifying sorting and recycling at end-of-life. This breakthrough supports the industry in meeting ambitious recycling and waste reduction targets outlined in the EU’s Packaging and Packaging Waste Regulation (PPWR).

“This technological step change paves the way for more circular, high-performance, and resource-efficient packaging solutions,” said Erik Van Praet, Senior Vice President Innovation & Technology at Borealis. “It underscores our strategic commitment to sustainable innovation, driven by continuous investment in cutting-edge research and development.”

As part of the launch, Borealis is introducing two development materials that showcase the potential of Borstar Nextension PE. The first offers double the toughness of earlier metallocene PE materials while maintaining stiffness and processability, including superior bubble stability and throughput.

With its exceptional mechanical performance and downgauging potential, this material is ideally suited for industrial and food packaging applications such as Form, Fill & Seal (FFS) and frozen food packaging.

The second features a breakthrough sealing profile that reduces sealing initiation temperature by more than 15 percent compared to first-generation metallocene PE. Combined with excellent mechanical properties, this enables faster packaging speeds, best-in-class hot tack performance, and outstanding suitability for lamination, FFS, and food packaging.

“Borstar Nextension PE technology will expand our portfolio with highly efficient and recyclable solutions,” added Craig Arnold, Executive Vice President Polyolefins, Circular Economy Solutions and Base Chemicals. “This is just the beginning of a robust innovation pipeline that will serve customer needs across multiple industries.”

The launch of Borstar Nextension PE builds on the success of Borstar Nextension Polypropylene (PP) technology, introduced in 2022, and represents another milestone in Borealis’ drive to create innovative, circular, and resource-efficient material solutions for a sustainable future.