Coveris, a major European packaging producer, has introduced PolyFlex Thermoform, an innovative thermoforming format created with Signature Flatbreads and Al’Fez for a selection of flatbread products. The launch represents an important development in bakery packaging, providing a recycle-ready, high-barrier alternative for food manufacturers.
Signature Flatbreads, the UK’s largest flatbread producer, worked alongside Al’Fez, the premium food brand inspired by North African and Middle Eastern cuisine, and Coveris to commercialise the new format. PolyFlex Thermoform is now available on three Al’Fez flatbread products through retailers in the UK and EU. These include Turkish-Style Flame Baked Mini Flatbreads, featuring prominent Al’Fez branding and appealing serving imagery designed to attract shoppers and strengthen shelf presence.
The new structure uses a nylon-free, recycle-ready polyolefin design. Its lidding film combines polyethylene and polypropylene, while the base web is made from monomaterial polyethylene. This configuration is intended to replace the non-recyclable structures commonly used for thermoformed food packaging.
In the UK, the packaging can currently be recycled through soft plastic collection points located at the front of major retailers. Its development supports the government’s Simpler Recycling programme, which is due to require kerbside collection of soft plastic films and bags from 2030 after the initial 2027 deadline was delayed. By reducing packaging impact and providing a recycle-ready solution, PolyFlex Thermoform also supports obligations under Extended Producer Responsibility (pEPR) in the UK and the EU Packaging and Packaging Waste Regulation (PPWR).
Coveris’ Film and Food Science Labs in Winsford and Gainsborough supported the material’s development and testing. The resulting structure was engineered to match or exceed the performance of existing packaging formats. It protects product quality through effective barrier performance, delivers a validated 12-week shelf life and runs reliably on established packing equipment. The solution also provides heat and puncture resistance, as well as strong clarity that allows consumers to see the product clearly.
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 demonstrates how collaboration can support progress across food manufacturing trends and wider food and beverage industry trends. Coveris, Signature Flatbreads and Al’Fez have combined packaging performance with environmental responsibility, responding to the growing importance of food and drink sustainability, evolving food and drink regulations and advances in food processing technology.
PolyFlex Thermoform has been shortlisted for ‘Best New Concept’ at the UK Packaging Awards, which will take place on 7th October. It is also a finalist in the ‘Sustainable Product Design’ category at the Plastics Industry Awards, with the awards ceremony scheduled for 20th November. The launch reflects continued food and drink industry innovation across food and drink packaging, while also responding to changing food distribution trends, food and drink marketing priorities and food and drink consumer trends.