2024: Production records and partnerships

Brad Leesman celebrates the successes of 2024 and the promise of 2025   

As 2024 draws to a close at Baystar, Brad Leesman reflects on some of the key highlights: from setting new production records to developing high-performance custom solutions for clients to diversifying and expanding the company’s portfolio.

The commercial director for the Pasadena, Texas-based integrated producer says he’s most proud of how well their products have been received in the marketplace. Baystar brought its new 625 kt/y PE production bay online in late 2023. Bay 3 features Borstar® 3G technology, delivering a broad range of products to help meet market demand for lighter, more durable, more flexible and more sustainable plastics.

“Bay 3 offers some very distinct advantages which I think have captured the attention and interest of the North American customer,” Brad explains. “Our partners have been very receptive to the idea of a high-quality PFAS-free product, one that does not have any PPA or performance additives, is highly versatile, and can be designed to fit their specific needs.”

Record-Breaking Production

Bay 3 officially hit its operational stride earlier in 2024 and coupled with consistent performance from Bay 1 and Bay 2, “we achieved multiple record-breaking months in both production and sales,” Brad says. Adding over a billion pounds of new production capacity to an already competitive market is no small feat, and successfully placing that product is a testament to the strong connections between Baystar’s production and technology crew and the sales and commercial teams.

Baystar’s ethane cracker facility in Port Arthur has also provided a strategic advantage, providing reliable local feedstock for all three production units. But Brad is quick to point out that success in 2024 wasn’t just measured by production; it was also about building relationships.

“Close collaboration between our sales, business development, and marketing teams enabled deeper engagement with our customers. We’re having in-depth discussions with our clients and their technical teams, listening to them and understanding their needs. That personal approach is really core to our efforts,” Brad says. “I think our size is a distinct advantage. We’re nimble and have the ability to adapt quickly to create tailored solutions.”

New Products in ‘25

Diversifying the product portfolio was a major focus in 2024. Leveraging the flexibility of Bay 3, Baystar developed new grades for conduit and film products and tapped into new markets such as geomembrane and other specialty applications. In addition to expanded offerings for the film market, Baystar is also working toward the launch of a new pressure pipe resin in 2025 — currently pending final approvals and expected to be available by the third quarter.

“Looking ahead, we see opportunities to specialize Bay 1 and Bay 2 production, freeing them up for more niche applications while Bay 3 handles high-volume demands. We’re also excited about the ability for Bay 3 to replace high-pressure LDPE, which will open doors to new efficiencies for our customers.”

As with every year in commodities, Brad says there will be challenges to face in 2025, including an evolving regulatory environment and continued global economic volatility. The North American market also faces oversupply issues with new production capacity coming online. But Brad says the Baystar team sees challenges as an opportunity to showcase how they stand out in the market.

“We stay agile, adaptable, and laser-focused on delivering value to our customers,” he says. “We value problem-solving across all functions, no matter what your role is you can contribute to making us better.”

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