Borealis announces rollout of its Borstar Digital Twin program

Vienna, Austria – Continuing to push the boundaries of digitalization and AI-driven innovation in operational processes, Borealis announced the global rollout of its Borstar® Digital Twin program.

This cutting-edge suite of solutions combines the latest technology with deep process expertise, enabling Borealis plants to achieve world-class efficiency and productivity. By integrating artificial intelligence (AI), real-time optimization, and powerful data analytics, the Borstar Digital Twin marks a major milestone in Borealis’ digital transformation journey.

This innovative platform creates a virtual replica of the production process, enabling real-time monitoring, predictive insights, and advanced simulations.

The Borstar Digital Twin empowers Borealis to:

Optimize performance through data-driven decision-making and process simulations.
Enhance safety by predicting potential issues before they occur.
Advance sustainability by reducing waste, energy consumption, and environmental impact.
Accelerate innovation with faster product development and virtual operator training.
A New Era of Digitalization in Operations
Launched in 2023 and focusing on Borealis’ proprietary Borstar® technology for producing polyethylene and polypropylene, the Borstar Digital Twin program was designed to ensure plants operate at peak efficiency. Now, in 2025, Borealis has reached a tipping point: the company’s digital maturity now enables the successful global scale-up of this innovative solution across all Borstar units, including those operated by licensees Baystar™ and Borouge. This marks a new phase where digital ways of working are becoming the norm in Borealis’ core production processes.

“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,” says Wolfram Krenn, Executive Vice President Operations at Borealis.

Stefan Doboczky, CEO at Borealis, puts this into a broader perspective: “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.”