in partnership with Borealis


Less cost, better performance — more sustainable

EcoCore® is used to reduce the weight of solid plastic mouldings, increase their performance and provide a balance of the two.

Less cost

EcoCore® reduces the cost of mouldings in two ways. The foam core cuts the amount of material required by up to 70% when compared to solid walled containers. And, the unique way that foaming is controlled also allows cycle times comparable with solid mouldings to be used. This is typically 80% less than other foam injection moulding processes.

High performance

EcoCore® creates thick moulding walls from very small amounts of plastic. For example, thin solid 1mm walls can be increased to around 2.6 mm without adding extra material.


Compared to thin wall plastic mouldings, EcoCore® alternatives using the same amount of material have:

  • Less thermal transmittance — foaming creates thermal insulation to keep packaging contents hot or cold for longer. It also protects against high temperatures to preventing scalding and burning

  • Higher bending strength and stiffness — less flex and greater load resistance

  • More compressive strength — greater resistance to buckling and higher top load capacity

  • Greater impact resistance — less likely to break if dropped

Using EcoCore® typically reduces the amount of plastic needed to make products or packaging with the same performance as solid alternatives. This reduces the weight of plastic used along with both transportation costs and environmental impact.

To maximise consumer appeal, mouldings made using EcoCore®  have outer and inner skins with textures ranging from gloss to orange peel.


The outer skin can also be decorated through common processes such as:

  • Indirect flexo printing

  • Dry offset printing

  • In-mould labelling

  • Pad printing

  • Screen printing

  • Digital printing

  • Painting

Easy to use

Most plastics manufacturers can use EcoCore® without additional investment in equipment or machinery. Only specific features within mouldings and the mould tool, as well as unique process settings, are required.

EcoCore® also uses polypropylene plastic that is low cost, widely available and has been proven safe for even the most demanding food and medical applications.

More sustainable

Less material means reduced consumption of non-replaceable natural resources. And the amount of energy needed for manufacturing, that typically contributes to CO2, is cut.  

EcoCore® mouldings are widely recycled and can be made with recycled polypropylene. As such it supports circular economy initiatives that lessen carbon emissions by encouraging plastic recovery and reuse as well as minimising landfill and the burning of waste. In addition recycling and reuse also reduce littering that adversely affects both land and marine habitats.

Limitless applications

EcoCore® creates limitless opportunities for innovative products and packaging with a competitive edge in key sectors:​

  • Beverages — hot and cold to-go drinks cups

  • Food — noodle pots and microwave meals

  • Industrial — tubs and paint containers

  • Healthcare — medicine and sharps containers

To find out how EcoCore® will create opportunities for you get in touch

Up to

70 %

Less material than solid mouldings

Less than

10 sec  

Cycle time


1.2 X

More thermal protection


5.5 X


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