Integra Plastics AD in Bulgaria, a member of the Borealis group, will convert its mechanical recycling facility to polypropylene starting in October 2025. The project includes the installation of Borealis' proprietary Borcycle M technology. The upgraded line will transition production from recycled low-density polyethylene to value-add and premium grades of recycled polypropylene intended for demanding applications. According to Borealis, Borcycle M enables the upcycling of post-consumer polyolefin waste into high-quality materials with a significantly lower carbon footprint than virgin-based alternatives. Following the upgrade, output is expected to exceed the current capacity of 20,000 metric tons. The move is intended to address growing demand for rPP in consumer packaging, mobility and appliances, with further enhancement of recycled material properties possible through integration with Borealis' compounding business. It is also positioned to support customers ahead of emerging national and international requirements, including the EU Packaging and Packaging Waste Regulation and the End-of-Life Vehicle directive.
The rPP materials have a significantly lower carbon footprint than virgin-based alternatives, helping Borealis’ customers reduce their environmental impact
Technology scope
The upgrade centers on deploying Borcycle M, Borealis' advanced mechanical recycling technology for post-consumer polyolefin streams. The transition will shift Integra's output from rLDPE to recycled polypropylene, enabling production of value-add and premium rPP grades. The capacity increase beyond 20,000 metric tons is aimed at improving supply security for applications that require consistent performance and quality.
Market and regulatory context
Borealis positions the Integra upgrade as part of its broader approach to expand availability of recycled materials for consumer packaging, mobility and appliances. By integrating recycled feedstocks with its compounding capabilities, the company plans to further tailor properties to application needs. The initiative is also framed as supporting customers' preparedness for future compliance with the EU Packaging and Packaging Waste Regulation and the End-of-Life Vehicle directive.
"This upgrade will give our customers reliable access to premium recycled materials. In combination with Borealis’ superior products and compounding expertise, we’re in a unique position to serve our customers in their quest to transition to sustainable solutions," said Dirk Langhammer, Borealis Vice President Circular Economy Solutions.
