Coveris has collaborated with bakery firm Signature Flatbreads and ingredients maker Al’Fez to develop thermoformed packaging for flatbreads.
PolyFlex Thermoform has been introduced on three Al’Fez flatbread varieties sold through retailers in the UK and EU, including Turkish-Style Flame Baked Mini Flatbreads.
The nylon-free polyolefin structure uses PE and PP in the lidding film with a mono-material PE base web. Coveris said it was developed as an alternative to non-recyclable structures used in thermoformed food packaging.
The packaging is currently recyclable through front-of-store soft plastics collection points at major UK retailers. It has also been developed in line with the UK’s Simpler Recycling initiative, which will introduce mandatory kerbside collections for soft plastics films and bags from 2030.
Improved performance
Development and validation work was carried out at Coveris’s Film and Food Science Labs in Winsford and Gainsborough.
The company said the structure provides equivalent or improved performance compared with existing packaging, including a validated 12-week shelf-life and consistent performance on existing packing lines.
The packaging also provides heat and puncture resistance, as well as optical clarity for product visibility, according to Coveris.
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.
‘Delivers across every requirement’
“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.”
PolyFlex Thermoform has also been shortlisted for Best New Concept at the UK Packaging Awards, taking place on 7 October, and is a finalist in the Sustainable Product Design category at the Plastics Industry Awards in November.
The launch follows Coveris’s acquisition of German cast PP film producer Gefo Folienbetrieb in June, which the company said would expand its CPP film capabilities for applications including lidding and bakery packaging.
Coveris said at the time that demand for recyclable mono-material packaging was continuing to grow across Europe.
