Coveris replaces nylon laminates with mono-PE thermoform for flatbreads

UK – Coveris has introduced a thermoforming format that swaps conventional nylon-based laminates for a nylon-free polyolefin structure, developed with Signature Flatbreads and deployed across three Al’Fez flatbread lines sold in the UK and EU.

The construction separates into two compatible layers: lidding film combining polyethylene and polypropylene, and a base web made entirely from monomaterial polyethylene. 

That combination allows the pack to pass through front-of-store soft plastic collection points at major UK retailers, a route unavailable to mixed-polymer thermoforms. 

Polyamide, commonly used to add puncture and thermal resistance, is absent from the structure, removing the layer that typically prevents mechanical separation in recycling facilities.

Twelve-Week Shelf Life Validated Before Launch

Coveris developed and validated the format through its Film and Food Science Labs in Winsford and Gainsborough. 

Testing covered barrier performance, a validated 12-week shelf life and compatibility with existing packing lines. 

The pack also delivers heat and puncture resistance alongside optical clarity, allowing shoppers to see product while the format withstands the mechanical demands of bakery distribution. 

Turkish-Style Flame Baked Mini Flatbreads is among the products using printed packaging with Al’Fez branding and serving-style imagery.

Regulatory Alignment Covers UK EPR and EU PPWR

The format supports the United Kingdom’s extended producer responsibility requirements and the European Union’s Packaging and Packaging Waste Regulation. 

Fibre and mono-material formats that pass through established collection streams typically attract lower fee bands under both frameworks, making recyclability a commercial as well as environmental consideration for bakery brands operating across both markets.

Technical Director Frames Launch as Bakery Breakthrough

Mark Robinson, UK flexibles technical director at Coveris, said the launch represented a significant advancement in thermoforming packaging and a new solution for the bakery sector in high-barrier applications. 

He added that the company had worked collaboratively with Signature Flatbreads to ensure the format delivered across every requirement, from efficient packing through to shelf-life validation and overall functionality. 

He noted it was rewarding to see the recycle-ready solution fully launched, aligned with the company’s No Waste strategy.

Last month, Coveris produced and delivered a mono-material sleeve for Dr Beckmann’s launch in the liquid fabric softener segment in France, with the project moving from initial design to market launch within six months.

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