Coveris launches recycle-ready flatbread packaging

Coveris has launched PolyFlex Thermoform, a recycle-ready thermoforming packaging solution developed with Signature Flatbreads and Al’Fez for a range of flatbreads. The introduction brings a nylon-free, high-barrier structure to bakery applications that have typically relied on non-recyclable thermoformed packaging.

The packaging has initially been introduced for three Al’Fez flatbread varieties sold by retailers in the EU and UK. These include Turkish-Style Flame Baked Mini Flatbreads, with a printed design combining Al’Fez branding and serving-style imagery. Signature Flatbreads, a UK flatbread manufacturer, and Al’Fez, a food brand inspired by North African and Middle Eastern cuisines, worked with Coveris to bring the solution to market.

PolyFlex Thermoform combines a polyethylene and polypropylene lidding film with a monomaterial polyethylene base web. According to Coveris, the polyolefin structure is intended to replace non-recyclable formats used in thermoformed food applications while retaining the barrier and mechanical properties required for the product and packing process.

Recyclability and regulatory requirements

In the UK, the packaging can currently be recycled through front-of-store soft plastics collection points operated by major retailers. It was developed in line with the UK government’s Simpler Recycling initiative, under which mandatory kerbside collection of flexible plastic films and bags is scheduled to begin in 2030, following the postponement of the original 2027 target.

Coveris states that the recycle-ready format and the reduction in the overall packaging impact support compliance with the UK’s Extended Producer Responsibility framework for packaging, known as pEPR, and the requirements of the EU Packaging and Packaging Waste Regulation, PPWR.

Barrier performance and line compatibility

Development and validation were supported by Coveris’ Film and Food Science Labs in Winsford and Gainsborough, UK. The material was engineered to provide performance equivalent to or better than the structures it is intended to replace.

Testing covered the barrier properties needed to maintain product quality, a validated shelf life of 12 weeks and consistent operation on existing packing lines. The structure also provides heat and puncture resistance, while its optical clarity is intended to maintain product visibility at the point of sale.

Mark Robinson, UK Flexibles Technical Director at Coveris, said: "The launch of PolyFlex Thermoform is a significant advancement in thermoforming packaging and a new solution for the bakery sector for high-barrier applications. We have worked collaboratively with Signature Flatbreads to ensure PolyFlex Thermoform delivers across every requirement, from efficient packing through to shelf-life validation and overall functionality. It is rewarding to see the recycle-ready solution now fully launched aligned with our No Waste strategy".

The project reflects cooperation between Coveris, Signature Flatbreads and Al’Fez on a packaging format designed to combine functional performance with improved recyclability.

Award nominations

PolyFlex Thermoform has been shortlisted in the "Best New Concept" category at the UK Packaging Awards, scheduled for 7 October. It is also a finalist in the "Sustainable Product Design" category at the Plastics Industry Awards, whose ceremony is scheduled for 20 November.