Coveris is expanding its portfolio within its No Waste mission by introducing MonoFlex Thermoform monomaterial packaging for tortillas. The new structure replaces non-recyclable thermoformable mixed-material laminates while maintaining the existing product shelf life. The project was developed in cooperation with a tortilla producer seeking an alternative to previously used polyamide and polypropylene structures. The key requirement was a recyclable material that would also deliver at least six months' shelf life for a product with a low level of preservatives. The Coveris team conducted extensive in-use testing at the Food Science Lab at the Gainsborough site, the results of which led to the selection of a monomaterial top web and a thermoformable base web. During testing, the material effectively reduced the risk of mould growth over the required period while allowing waste to be directed into a single, harmonised recycling stream.
The new pack features enhanced puncture resistance and barrier properties that protect the product and extend shelf life. The MonoFlex Thermoform construction is compatible with existing packaging lines, enabling implementation without impacting packaging speed. Both the top and base webs can be printed by flexography, including HD quality, or by gravure. Surface finishes are available in matt, gloss, and with tactile varnish.
"We are very pleased with the successful commercial launch of MonoFlex Thermoform for tortillas. It is a sustainable alternative to non-recyclable materials that provides the same product shelf life while enabling more resource-efficient use, helping customers achieve their sustainability goals. This product demonstrates the benefits of collaboration between Coveris manufacturing sites and our specialists at the Film Science Lab, resulting in new, high-performance, sustainable packaging," said Katja Killian, Business Development Director in the Flexibles Business Unit (BU Flexibles) at Coveris.
Monomaterial packaging for tortillas
