Borstar® Nucleation Technology

Based on its proprietary Borstar® technology, Borealis has developed a nucleating approach resulting from its own research – Borstar Nucleation Technology.

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What Is Borstar Nucleation Technology

The nucleating effect of Borstar Nucleation Technology is obtained in the polymerization reactor (in situ) during the manufacture of polypropylene (PP). This is in contrast to the standard approach of adding a nucleating agent during pelletization. Borstar Nucleation Technology has a number of advantages compared with conventional nucleation:

  • stronger nucleation effect, resulting in higher crystallization temperature, faster crystallization process and fine spherulitic superstructure
  • consistent and better dispersion of the nucleating agent
  • inert and thereby no reaction with other additives such as color master batches
  • low taste and odor
  • full compliance with food contact regulations
  • Borstar Nucleation Technology

    Borstar Nucleation Technology nucleated (left) versus non-nucleated PP (right).

    Borstar Nucleation Technology

Scope of Borstar Nucleation Technology

Borstar Nucleation Technology-based PP demonstrates benefits in a range of applications with the Borealis portfolio of high-performance PP homopolymers and heterophasic polymers for thin wall packaging, automotive, and sewage pipe segments.

The improved stiffness of these materials allows for lower wall thicknesses, enabling downgauging of the end product. Furthermore, this solution enables significant reduction in cycle time, helping molding customers improve their resource efficiency and reduce their carbon footprint, adding value to the end product for brand owners.

Why Borstar Nucleation Technology?

For converters, Borstar Nucleation Technology enables more efficiency and sustainability in production through:

  • increased stiffness without negatively affecting the drop impact resistance, thus enabling downgauging and thereby material savings
  • up to a 10% reduction in energy consumption through the possibility of reducing the extruder temperature (depending on the equipment at the converter)
  • 10-20% cycle time reduction (mainly through reduction of cooling time and easier demolding due to faster crystallization)
  • limited impact of coloring on dimensional stability, allowing fast color change during production without the need to change process parameters