From the Sector

• Proprietary Borstar® Nextension polyethylene (PE) technology delivers superior performance and processability, enables downgauging and design for recycling – meeting the evolving demands of flexible packaging applications
• Borealis introduces development materials with superior toughness and sealability
• This marks the launch of a dynamic innovation pipeline across industries

Borealis proudly unveils its groundbreaking Borstar® Nextension Polyethylene (PE) technology, representing a significant leap forward in polyolefin innovation. 

Building on the proven performance of Borstar® technology, the new Borstar Nextension PE platform incorporates proprietary single-site catalysts developed by Borealis. This breakthrough technology marks a new era in advanced polyethylene solutions, delivering superior toughness, sealing performance, and enhanced processability for packaging solutions that enable downgauging, improve cost efficiency, and support design for recycling—addressing the critical needs of today’s packaging industry.

Borstar Nextension PE technology sets new standards by enabling mono-material solutions that can replace existing multimaterial products, thus making it easier to sort and recycle at the end of life. Crucially, this supports the packaging industry to meet the recycling and waste reduction targets set out 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,” says 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.”

Introducing next-generation development materials
Borealis introduces Borstar Nextension PE technology with two high-performance development materials, tailored to meet evolving market needs:

• A cutting-edge solution that delivers double the toughness of first-generation metallocene PE materials, while maintaining stiffness and excellent processability, including superior bubble stability and throughput. With its unique mechanical performance and strong downgauging potential, this new material enables more sustainable, fully recyclable packaging with excellent performance characteristics. Designed for industrial and food packaging applications, it is ideally suited for Form, Fill & Seal (FFS) and frozen food packaging.
• An advanced solution featuring a breakthrough sealing profile that reduces sealing initiation temperature by over 15% compared to first generation metallocene PE. This, in combination with the material’s outstanding mechanical properties, enables faster packaging speeds, best-in-class hot tack performance – making it perfectly suited for lamination, FFS, and food packaging.

“Borstar Nextension PE technology will expand our portfolio with highly efficient and recyclable solutions,” adds 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.”