This project emerged from a strategic partnership with a tortilla wrap manufacturer aiming to develop a more sustainable food and drink packaging solution. The primary challenge lay in sourcing a recyclable material while ensuring the tortilla maintains a shelf life of at least six months, with minimal preservatives. After thorough performance testing at Coveris’ Food Science Lab in Gainsborough, UK, the team determined that a monomaterial-based top and base thermoforming film was the most effective option. This innovative packaging provided robust protection for the sensitive tortilla wraps against mould throughout the testing phase while facilitating recycling within the same waste stream.
The packaging solution boasts several significant benefits. It features advanced barrier properties that extend product protection and shelf life, alongside strong puncture resistance. Furthermore, MonoFlex Thermoform allows for a seamless transition on packing lines from other materials, ensuring compatibility with existing systems without sacrificing packaging speeds. The packaging is available as either fully printed or unprinted top and base film, supporting conventional as well as HD flexographic or rotogravure printing. Options for matte, gloss, and tactile lacquer finishes enhance consumer appeal and create an attractive on-shelf presentation.
“We are extremely pleased with the successful commercial launch of MonoFlex Thermoform for tortilla wraps. This sustainable alternative to non-recyclable materials delivers the same shelf-life performance while saving resources and helping customers meet their sustainability targets. It also showcases the advantage of collaboration between Coveris’ production sites and Film Science Lab expertise, enabling the development of high-performance sustainable packaging solutions,” commented Katja Killian, BU Flexibles Business Development Director at Coveris.
