Borealis Expands AI-Powered Borstar® Digital Twin Program Globally

Borealis has announced the global rollout of its AI-powered Borstar® Digital Twin Program, marking a significant step in the digital transformation of polymer production. The technology integrates artificial intelligence, real-time monitoring and advanced data analytics to make Borstar® production processes more efficient, stable and sustainable.

Originally introduced in 2023, the Borstar Digital Twin is designed for production units using the company’s Borstar® technology for polyethylene (PE) and polypropylene (PP). Following successful implementation across its European sites, Borealis is now deploying the system across all Borstar® plants worldwide, including locations operated by partners and licensees such as Baystar™ and Borouge.

The Digital Twin creates a virtual representation of real-time production conditions. This enables:

• Continuous real-time performance tracking
• Predictive analytics that identify potential issues before they occur
• Scenario-based simulations to support operational decisions
• Reduced unplanned downtime
• Improved process stability and product quality

By using AI-driven data models, the system supports operators in making faster, data-based decisions. This leads to:

• Higher operational efficiency
• Improved safety performance
• Lower energy use
• Reduced material losses and waste

These advantages contribute directly to Borealis’ broader sustainability and performance targets.

According to the company, the rollout is a cornerstone of its digitalization strategy.

Wolfram Krenn, Executive Vice President Operations at Borealis, highlights the operational impact:

“By embracing the Borstar Digital Twin, Borealis is not just adopting new technology – it’s transforming plant operations. By combining AI-driven predictions with rigorous process models, the Borstar Digital Twin enables plants to run at higher efficiency, achieve faster and more controlled grade transitions, and deliver consistently prime product quality. Additionally, real-time monitoring allows early detection, prediction, and mitigation of process and equipment anomalies, resulting in fewer unplanned shutdowns and greater reliability.”

CEO Stefan Doboczky emphasizes the benefits for customers:

“Borstar Digital Twin turns technology into a customer advantage. It delivers speed, reliability, and quality - helping our customers succeed. That’s how we put our We4Customers strategy into action.”

The global implementation of an AI-based Digital Twin across polymer production lines illustrates how digitalization, automation and Industry 4.0 are becoming integral to modern manufacturing. For the plastics industry, this development supports: 

• More resilient and responsive production systems
• Optimized use of resources
• Enhanced process transparency
• Progress towards climate and sustainability goals