01 Investment in High-Melt-Strength Polypropylene for Foam Applications Polypropylene foam production is moving toward specialized resin grades that can deliver better melt strength and foamability. High-melt-strength polypropylene can support lightweight foam structures while maintaining mechanical performance, creating opportunities for applications that require a combination of low weight, durability, and processing efficiency. This material-development direction is expanding the technical capabilities of polypropylene foam beyond conventional grades.The company said the line would triple its supply capability for fully recyclable HMS polypropylene used in lightweight foam solutions for automotive, consumer goods, and construction applications.
02 Increasing Use of EPP in Reusable Packaging and Logistics Expanded polypropylene foam is gaining attention in returnable packaging because its resilience allows containers and protective inserts to withstand repeated handling. Unlike single-use protective materials, EPP packaging can be reused through multiple transport cycles while providing cushioning and thermal-insulation properties. This is creating opportunities for polypropylene foam in logistics systems that prioritize repeated use and product protection.In January 2026, Borealis reported the successful completion of a reusable-cup pilot at Messe Düsseldorf using 50,000 durable, lightweight cups made from foamable polypropylene. The system included collection, cleaning, reuse, and recycling processes, demonstrating the potential for foamable polypropylene in practical reuse systems.
01 Expansion of EPP Use in Consumer Electronics and Protective Packaging Demand for polypropylene foam is increasingly supported by applications outside traditional automotive components. Growth in consumer electronics, telecommunications equipment, batteries, and home appliances is therefore creating additional demand channels for polypropylene foam and reducing the industry's dependence on automotive applications.In 2025, JSP reported that non-automotive EPP applications in China were growing faster than automotive applications, with displays, batteries, telecommunications equipment, and home appliances identified among the important application areas. The company also highlighted EPP's use as a cushioning material for these products.
01 Polypropylene Feedstock Price Movements Affect Foam Manufacturing Economics Polypropylene foam producers remain exposed to changes in the underlying polypropylene resin market because resin is a fundamental production input. Variations in polymer supply, downstream purchasing, production rates, and propylene costs can influence material pricing and therefore affect the economics of foam processing. This creates uncertainty for manufacturers that need to maintain stable product pricing while managing fluctuating input costs.In October 2025, LyondellBasell introduced a new polypropylene grade designed for packaging and industrial applications, highlighting the continuing development of differentiated polypropylene materials in response to changing customer requirements for strength, durability, and processing performance.
01 Development of EPP Components for Electric-Vehicle Battery Systems Electric vehicles are creating new opportunities for polypropylene foam beyond conventional cushioning and impact-protection applications. EPP can be designed into battery-related components where low weight, thermal insulation, dimensional stability, and impact absorption are required. The expansion of EV engineering therefore gives foam manufacturers access to applications that were less prominent in conventional internal-combustion vehicles and supports polypropylene foam market growth.In 2025, JSP reported that EPP was increasingly being used in battery applications in China, including battery packaging for battery energy-storage systems, while also identifying further expected growth in new-energy vehicle and energy-storage applications.
01 Meeting Recyclability Requirements Across Automotive Supply Chains Polypropylene foam manufacturers face increasing pressure to ensure that foam components can be recovered and recycled at the end of their useful life. Automotive applications are particularly challenging because foam components can be integrated into larger assemblies containing multiple materials. Designing components for separation, maintaining material purity, and establishing effective collection systems are therefore important to achieving higher recycling rates.In June 2025, Borealis announced that its new HMS polypropylene foam capacity was specifically designed around a fully recyclable mono-material structure, supporting design-for-recycling requirements across automotive, consumer goods, and construction applications.
May 2026 JSP Corporation expanded its polypropylene foam portfolio with lightweight materials for automotive and protective packaging applications. The new products improve impact resistance and recyclability. They strengthen the company's engineered foam business.
April 2026 BASF introduced advanced expanded polypropylene (EPP) foam solutions for electric vehicles and industrial applications. The materials enhance energy absorption while reducing component weight. They reinforce the company's sustainable materials portfolio.
February 2026 Kaneka Corporation launched next-generation polypropylene foam products with improved thermal insulation and durability. The new materials support automotive, construction, and consumer goods applications. They expand the company's foam materials business.
October 2025 Hanwha Solutions expanded production capacity for expanded polypropylene foam to meet growing demand from the automotive and packaging industries. The investment improves manufacturing efficiency and supply reliability. It strengthens the company's advanced materials portfolio.