Coveris, Signature Flatbreads and Al’Fez have applied PolyFlex Thermoform, a high-barrier and recyclable thermoforming packaging solution, to flatbread products.
The packaging is a nylon-free polyolefin structure that combines a lidding film made from polyethylene and polypropylene with a mono-polyethylene base web. This format intends to replace non-recyclable packaging traditionally used in thermoformed food applications.
Currently, PolyFlex Thermoform can be recycled via front-of-store collection points for flexible plastics at major UK retailers. It was developed in line with the UK Government’s Simpler Recycling initiative, which is expected to introduce mandatory kerbside collection for flexible plastic films and bags from 2030.
In turn, the packaging is set to align with the EU Packaging and Packaging Waste Regulation and the UK’s Extended Producer Responsibility (pEPR) requirements.
Additionally, the material was designed to match or improve upon the performance of incumbent structures; these include a validated twelve-week shelf life for flatbread products, barrier properties, heat and puncture resistance, and high optical clarity.
Coveris’ Film and Food Science Labs in Winsford and Gainsborough, UK, supported the packaging’s development and validation.
“The launch of PolyFlex Thermoform is a significant advancement in thermoforming packaging and a new solution for the bakery sector for high-barrier applications,” said Mark Robinson, UK Flexibles technical director at Coveris.
“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 new packaging has initially launched across three Al’Fez flatbread varieties sold in the EU and UK – including the Turkish-Style Flame Baked Mini Flatbread product, with the printed design that displays Al’Fez branding alongside serving-style imagery. This is expected to stand out on shelves and appeal to consumers.
In another development, Modern Milkman recently adopted Treetop Biopak’s home-compostable bread bag. Apparently, the packaging breaks down in around twelve months without leaving microplastics or pollutants behind.
Coveris has also developed a mono-material sleeve solution for Dr Beckmann, said to use around 30% less material than conventional shrink sleeves and address current and evolving regulatory requirements.
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