Sulzer Chemical and Borealis have completed the development of an innovative process for the cost-effective extrusion of expanded polypropylene (ePP) beads. 

Polypropylene (PP) is a highly efficient material with advanced mechanical properties, making it ideal for reuse and recycling. To support the mass adoption of ePP, Sulzer Chemical has now launched a new innovative production line. The final solution jointly developed with raw material supplier Borealis supports the end market's efforts to more circular solutions and is expected to reduce manufacturing costs by as much as 60%. 

Unlike traditional autoclave production methods, Sulzer Chemical’s innovative system relies on direct gas-impregnated extrusion, providing an alternative that is easy to implement and has a fast return on investment. Foam molders, such as packaging manufacturers, can implement composite production lines to significantly reduce costs associated with material supply, warehousing, and intermediate transportation. Therefore, the company can provide ePP parts at a more competitive price while supporting the use of polyolefin applications that are easy to recycle.

Other benefits include complete control of ePP's characteristics, such as bulk density, closed cell content, and bead size distribution, as well as maximum flexibility in fine-tuning the formulation. In addition, a highly automated process reduces maintenance requirements and simplifies operations. In addition, the extruded beads can then be easily processed in a steam chamber molding machine with standard steam pressure to obtain molded bead foam products with specific shapes. In addition, Sulzer Chemical and Borealis are developing an alternative that can use carbon dioxide to support different customer needs and plant settings.

Christopher McArdle, Vice President of Polyolefin Strategy and New Business Development at Borealis, said: "Life needs progress. This innovation will further promote the adoption of our PP foam solutions and support the transition of plastics to a circular economy. This is what we are making for a more sustainable Reinvent the way of life."

Torsten Wintergerste, President of Sulzer’s Chemical Technology Department, concluded: “We are very satisfied with the advanced ePP production line jointly developed with Borealis. The results of this cooperation truly prove the extensive expertise of the two companies. Use our latest solutions. , Customers will be able to benefit from cutting-edge equipment with enhanced performance and high-quality PP used to produce first-class foam."

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