Borealis and Trexel develop new reusable and fully recyclable lightweight bottle

Borealis and Trexel develop new reusable and fully recyclable lightweight bottle

• Monomaterial solution contains renewably-sourced polypropylene from the Bornewables portfolio of circular polyolefins
• Trexel employs its proprietary MuCell technology to deliver a range of lightweighting benefits
• EverMinds in action: reuse and design for recycling are focus of value chain collaboration

Borealis and Trexel, a leading expert in foaming injection and blow moulded parts, announce that they have co-developed a new plastic bottle based on a grade from the Bornewables portfolio of polyolefins made using renewable feedstocks derived 100% from waste and residue streams. The lightweight bottle – which will be showcased at the Borealis stand at the K 2022 in October – is reusable and fully recyclable. It boasts a significantly lower overall CO2 footprint because it is composed of renewably-sourced feedstock and produced in the foaming process.

The Bornewables portfolio of circular polyolefins helps reduce the carbon footprint while offering material performance equal to virgin polymers. Using Bornewables grades allows for design freedom and colour flexibility, and helps retain a premium look and feel. The grades – which are commercially available in Europe – help conserve natural resources because they are derived solely from waste and residue streams, for example from used cooking oil. Reusing waste already in circulation instead of fossil fuel-based feedstocks enhances the sustainability of applications made using the Bornewables grades.

The reusable new bottle developed by Borealis and Trexel retains its value over many life cycles thanks to the use of Trexel’s proprietary technology in tandem with Bornewables grades; as a material solution, the new bottle minimises the use of valuable raw materials. Moreover, converters consume less energy in the production process when using the MuCell technology. The bottle thus helps close the loop on plastics circularity by way of design for recycling, the use of renewable feedstocks, and excellent material performance across multiple life cycles.

“Reuse and recycling are core components of the integrated circular cascade model aligned with our EverMinds platform, which unites committed players across the entire value chain in accelerating the move to plastics circularity,” says Peter Voortmans, Borealis Global Commercial Director Consumer Products. “This project is an excellent example of how we are working with industry partners to solve the problem of plastic waste while delivering real value to our customers. Combining our polymers and recycling expertise with Trexel’s material processing know-how enables us to re-invent essentials for sustainable living.”

Trexel is a global leader in foaming thanks in part to its proprietary MuCell physical (as opposed to chemical) foaming process, which enables greater density reductions, improved mechanical properties, and attractive surface aesthetics.

The larger processing window facilitates its application to a wider range of products. MuCell foamed parts are recyclable and can thus be reintroduced into the polymer stream. The lightweighting benefits of foaming have become particularly compelling as the industry seeks to use less energy in production, minimise the use of materials, and also fulfil growing market demand for more sustainable packaging solutions.

“Having anticipated market demand for more sustainable plastic packaging, we have focused our development resources over the last several years on the circular sphere,” explains David Bernstein, Trexel Chairman of the Board and Interim CEO. “Our foaming solutions for blow moulding and thin-wall packaging enable brand owners and moulders to realise improved sustainability and enhanced product performance while delivering cost savings.”

K 2022 will take place from 19 to 26 October 2022 in Düsseldorf, Germany.

We invite you to “Innovate Collaborate Accelerate” together with us by visiting Borealis and Borouge, where the new bottle produced in collaboration with Trexel will be on display. Trexel can be found at the show.

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