Expansions: Borealis to boost XLPE capacity in Sweden; NYCOA starts up third reactor to expand specialty nylons

Austrian polymers firm Borealis is expanding its cross-linked polyethylene (XLPE) production at its Stenungsund site in Sweden, as part of a EUR200 million initiative aimed at enhancing XLPE and semicon assets across key European locations.

The expansion involves two major projects. The first project focuses on constructing a new production unit for medium-voltage (MV) power distribution cables. This unit will produce a new-generation homopolymer XLPE grade, with commercial availability expected in Q1 2027.

The second project increases capacity for advanced XLPE grades used in high- and extra-high voltage (HV and EHV) cable systems. These systems are crucial for reinforcing national grids and integrating renewable energy sources. Construction is set to complete in 2026, with commercial availability anticipated in 2027.

The expansion will improve local material availability within the EU, ensuring a steady supply to meet MV market demand.

These cables are essential for expanding transmission and distribution networks so they can integrate more renewable energy sources, support electrification, and ultimately deliver the energy transition. These investments build on the Stenungsund site’s long-standing expertise, where decades of research, advanced laboratories, and a skilled team have established it as a global centre of excellence for XLPE materials, it adds.

The expansions follow the upgrade of Borealis’ semiconductive compounding facilities in Antwerp, Belgium, which was completed earlier this year. Together with ongoing investments in Ruwais, UAE, these projects will double Borealis and Borouge’s ability to serve demanding power cable applications by 2027.

In other news, Nylon Corporation of America (NYCOA), a manufacturer of engineered nylon resins, has announced the start-up of a third reactor for the production of specialty nylons at its existing Manchester, NH headquarters facility. The new polymerisation line is expected to double capacity for NYCOA’s long-chain nylons and copolymers.

NYCOA’s expansion is part of a multi-phase business strategy to boost batch reactor capacity for specialty nylons including long-chain nylons and copolymers. NYCOA, a domestic supplier of nylon 6 and 6-based copolymers and compounds for wire and cable and filament extrusion since 1957, is undergoing a growth transformation by taking its material development and manufacturing know-how to a new level. The new capacity, which complements expansions in continuous nylon 6 production in Manchester, ensures a future supply of these new long-chain nylons for a range of markets including transportation, industrial, and sporting goods. The last phase of this capacity growth strategy will be a fourth reactor, also in Manchester, that is 75% complete and expected to start up in late 2026.

“This new production capability in specialty nylons expands our portfolio and enables us to meet a range of opportunities in the domestic market,” said Monica Kumar, President of NYCOA. “These new assets will ensure a dedicated supply to our customers.”

In alignment with its growing batch reactor production capability, the company will continue to expand its specialty nylon material offering with new product platforms such as NXTamid T nylon 6,12 and 6,10 grades, NY-Clear amorphous 6i/6t nylon for food packaging and automotive, and NXTamid L, which meets or exceeds the performance of nylon 12 and nylon 11 in many applications and offers a broad range of customisation options.Rounding out the long-chain nylon offering is the NY-Flex line, a polyether block amide (PEBA) copolymer with key uses in footwear, medical, and sports equipment.

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