Coveris, a leading European packaging manufacturer, has announced the launch of PolyFlex Thermoform, a new thermoforming packaging solution developed in collaboration with Signature Flatbreads and Al’Fez for a range of flatbreads. The launch marks a significant step forward in packaging, bringing a new recycle-ready high-barrier solution to the bakery sector.
Signature Flatbreads, the UK’s leading flatbread manufacturer, and Al’Fez, a brand known for premium foods inspired by the cuisines of North Africa and the Middle East, partnered with Coveris to bring the solution to market. The PolyFlex Thermoform packaging has initially launched across three Al’Fez flatbread varieties, available from EU and UK retailers. The launch includes Turkish-Style Flame Baked Mini Flatbreads with the printed design showcasing distinctive Al’Fez branding alongside enticing serving-style imagery for consumer appeal and stand-out presence within the category.
PolyFlex Thermoform is a recycle-ready, nylon-free polyolefin structure, combining polyethylene and polypropylene for the lidding film with a monomaterial polyethylene base web, designed to replace non-recyclable packaging typically used in thermoformed food applications.
The packaging is currently recyclable through front-of-store soft plastic collection points at major UK retailers. It has been developed in line with the UK government's Simpler Recycling initiative, which will introduce mandatory kerbside collections of soft plastic films and bags from 2030, following the postponement of the original 2027 target. By delivering a recycle-ready format and reducing overall packaging impact, the solution supports both the UK’s Extended Producer Responsibility (pEPR) and current EU Packaging and Packaging Waste Regulation (PPWR) requirements.
Development and validation were supported by Coveris’ Film and Food Science Labs in Winsford and Gainsborough, UK, with the material engineered to deliver equivalent or improved performance compared with incumbent structures. This includes maintaining product quality through effective barrier properties, achieving a validated 12-week shelf life and ensuring consistent performance on existing packing lines. The solution also offers strong heat and puncture resistance, alongside high optical clarity to support product visibility on shelf.
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”.
This launch reflects a shared commitment from Coveris, Signature Flatbreads and Al’Fez to developing packaging solutions that combine performance with responsibility, highlighting the value of close collaboration in driving more sustainable change within the industry.
PolyFlex Thermoform is shortlisted for ‘Best New Concept’ at the UK Packaging Awards, taking place on 7th October, and is a finalist in the ‘Sustainable Product Design’ category at the Plastics Industry Awards, with the ceremony taking place on 20th November.