The project resulted from close cooperation with a tortilla wrap manufacturer, seeking a more sustainable alternative to the previously used PA/PE structure. The primary challenge was identifying a recyclable material while ensuring a minimum six-month shelf life for a tortilla with low quantity of preservatives. Following extensive performance testing at Coveris’ Food Science Lab in Gainsborough, UK, the team opted for a monomaterial based top and base thermoforming film. This material successfully protected the sensitive tortilla wraps against mould throughout the required testing period while enabling recycling in the same waste stream.
The packaging solution offers several key benefits, including advanced barrier properties for extended product protection and shelf-life, as well as strong puncture resistance. Additionally, MonoFlex Thermoform allows a seamless switch on the packing lines from alternative substrates, maintaining compatibility with existing packing lines without compromising packaging speeds. Available as fully printed or unprinted top and base film, the packaging supports conventional and HD flexographic or rotogravure print with options for matt, gloss and tactile lacquer finishing, enhancing consumer appeal and producing an attractive on-shelf presentation.
“We are extremely pleased with the successful commercial launch of MonoFlexThermoform 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.