At Mercury Plastics, innovation has always been at the core of what we do. For more than 25 years, we’ve worked closely with Borealis, a global leader in advanced polyolefins, to advance crosslinked polyethylene (PEX-c) technology and meet the growing demands of plumbing, heating, and industrial markets across North America.
Expanding Capacity Through Innovation
To better serve our clients and prepare for continued growth, we recently expanded our electron beam (e-beam) processing capabilities with the installation of a 10 MeV IBA Rhodotron® accelerator at our Middlefield, Ohio, facility. This addition represents a major milestone for our company and a $15 million investment in the future of PEX-c manufacturing.
The new 10 MeV accelerator builds upon our existing 5 MeV e-beam, significantly increasing our processing capacity and enabling us to handle a broader range of materials and product geometries with even greater precision. As one of only a few manufacturers in North America with a captive, high-energy e-beam facility, we’re proud to offer our partners unmatched consistency, speed, and technical expertise in polymer crosslinking.
A Partnership Built on Technical Leadership
Our long-standing partnership with Borealis has been instrumental in helping us push the limits of material performance. For decades, we’ve relied on Borealis HE2590 resin, a high molecular weight polyethylene (PE) designed specifically for e-beam crosslinking. This resin delivers the strength, chemical resistance, and reliability our clients depend on in critical applications such as plumbing, heating, and appliance systems.
Together, we’ve built a partnership defined by mutual respect, innovation, and shared commitment to quality. One that continues to drive growth for both companies.
“The success of our 25-year partnership with Borealis is based on a shared commitment and mutual respect for innovation and quality. With the increased capacity made possible by the Rhodotron®, we will continue to work together with Borealis to support the growth of our evolving customers’ needs as well as our own.” —Jay Burnett, President of Mercury Plastics LLC
Why We Use Electron Beam Crosslinking
Electron beam crosslinking is at the heart of our polymer modification capabilities. By using a focused beam of high-energy electrons, we permanently alter the molecular structure of polyethylene. This forms chemical bonds that significantly enhance strength, heat resistance, chemical resistance, and dimensional stability.
Unlike chemical crosslinking methods, e-beam processing achieves these results without additives, leaving behind a clean, safe, and environmentally responsible material. The result is a thermoplastic product with thermoset-like performance and an extended service life.
Our crosslinking process improves:
- Heat and crack resistance
- Tensile and impact strength
- Chemical and chlorine resistance
- Compression set performance
- Dimensional stability
These benefits make e-beam crosslinking ideal for applications such as tubing, wire and cable, heat trace cable, plumbing components, seals, gaskets, and molded parts.
Demand for High-Performance Thermoplastics Continues to Grow
As demand for high-performance thermoplastics continues to grow, we remain focused on advancing our materials expertise and production capabilities to better serve our customers and partners. Our expanded e-beam facility strengthens our leadership in PEX-c manufacturing and opens new opportunities for polymer innovation across a range of industries.
“The winning combination of Mercury’s PEX-c leadership and Borealis’ material expertise will continue to enable growth for HE2590 in specialty pipe, tubing, and appliances throughout North America.”—John Webster, Global Commercial Director Infrastructure at Borealis
We’re proud of what this collaboration represents: two companies working together to deliver better materials, better performance, and better solutions for the industries that depend on them.
Read the full case study in collaboration with Borealis and Borouge here, or contact us today to discuss your PEX tubing needs!
