Packaging converter Coveris has moved its PolyFlex Thermoform material into bakery, launching a recycle-ready, nylon-free high-barrier pack for flatbreads developed with UK producer Signature Flatbreads and the Al'Fez brand. Coveris announced it on Sep. 30, 2026. The pack is live on three Al'Fez flatbread varieties sold through UK and EU retailers, including Turkish-style flame-baked mini flatbreads.
The structure uses a monomaterial polyethylene base web and a lidding film combining polyethylene and polypropylene. Coveris says this replaces the nylon-containing laminates normally used in thermoformed food packs. Coveris says testing at its Winsford and Gainsborough film and food-science labs showed a validated 12-week shelf life and consistent running on existing packing lines, with heat and puncture resistance and optical clarity comparable to or better than the incumbent pack. IN Food (Oct. 2) noted that line compatibility still leaves forming temperature, seal settings and web handling to requalify. Its view: the pack's long-term test will be seal rejects, downtime and product waste in routine production. Coveris has previously used similar mixed-polyolefin structures to replace nylon in block cheese packs.
Coveris says the pack can be recycled now through front-of-store soft-plastic collection points at major UK retailers. It frames the launch around UK packaging EPR, the Simpler Recycling program (mandatory kerbside film collection from 2030), and the EU Packaging and Packaging Waste Regulation. For tortilla and flatbread packers, the takeaway is a commercial example of a barrier thermoform without nylon that kept its shelf life. Most U.S. tortillas still ship in poly bags, so it applies mainly to thermoformed and premium flatbread SKUs. Read the Coveris release for specs and IN Food for the line-qualification view.
Coveris Signature Flatbreads Al'Fez