Borealis expands Fibremod capacity in Italy; introduces new grades

Plastics solutions provider Borealis has not only introduced a complete polypropylene (PP) portfolio for lightweight composite applications but it has also expanded production of Fibremod PP-LGF (long glass fibre reinforced polypropylene) at its Monza facility in Italy.

The necessity for vehicle weight reduction to improve fuel efficiency and thus enhance sustainability continues to grow, increasing the use of alternative, lighter materials in all areas of a car. Over the years, various materials, most commonly thermosetting polymers, have been used to replace steel and aluminium especially for high demanding structural and safety related parts. However, thermoplastic resins such as PP have been gaining in favour due to their excellent performance, easy processability and affordable costs.

With the launch of the material solutions for composite based applications, Borealis is leveraging its proprietary technologies and processes to offer a complete PP product package for advanced lightweighting of automotive parts.

The Austrian firm says it has been working closely with key value chain partners to develop materials for specific composite applications. The most promising area of development is seen to be in structural carriers, where the substitution of PP for conventional materials like steel and more expensive engineering plastics is being accelerated. In addition to collaboration with composite sheet and tape producers, to whom Borealis supplies its innovative PP resins, Borealis is in the advanced development stage in pilot projects with several Tier 1 suppliers.

Working closely with Brose, the Coburg, Germany-based firm known for its innovative mechatronics systems for doors and seats as well as electric motors, Borealis has supported the engineering of a PP composite and PP short glass fibre-based seat carrier solution replacing steel. Another PP composite sheet-based solution is under development, this time in combination with PP-LGF, for lightweighting of door carriers. Furthermore, the collaboration with Takata, one of the world’s leading suppliers of airbags, has led to the development of a next-generation airbag housing made of PP-LGF and composite sheet.

As one of Borealis’ most flexible specialty plants, the Monza production facility was first equipped with a Fibremod PP-LGF production line in 2013. It is now expanding its total Fibremod LGF capacity to 10 kilotonnes/year to follow the increased market demand. With the new capacity in Monza, Borealis will be able to provide further weight saving solutions with an extended product portfolio offer.

Launched in 2013, the Fibremod family of engineered short (SGF) and long (LGF) compounds is a cornerstone innovation. Fibremod PP-LGF is produced using a proprietary pultrusion technology to achieve high quality materials with excellent glass fibre impregnation, ultra-broad molecular weight distribution and increased fibre length in both pellets and final parts. The Fibremod PP-LGF also contributes to a more environment friendly production solution thanks to reduced processing temperatures, which require less energy when compared to alternatives such as engineering plastics and metal.

The new materials will be launched at Borealis booth at the automotive event: VDI Mannheim in Mannheim, Germany, from 9-10 March.