Coveris has launched a recyclable monomaterial thermoform packaging for tortilla wraps, extending its No Waste mission to a new application in bakery products.
The company’s new MonoFlex Thermoform replaces non-recyclable, mixed-material thermoforming substrates previously used in the segment. Developed in partnership with a tortilla wrap manufacturer, the packaging solution had to deliver sustainability gains without compromising shelf life.
The main challenge was to identify a recyclable structure that could maintain a minimum six-month shelf life for tortillas with low preservative content. After extensive trials at Coveris’ Food Science Lab in Gainsborough, UK, the team introduced a monomaterial top and base thermoforming film with high barrier properties. Tests confirmed that the structure effectively protected the product against mould for the required period, while enabling recycling in a single waste stream.
Coveris said the new material also provides strong puncture resistance and ensures a smooth transition on existing packing lines, supporting high-speed production without modifications. It is available in both printed and unprinted versions, compatible with flexographic and rotogravure printing processes, and can be finished in matt, gloss or tactile lacquers for shelf appeal.
Katja Killian, BU Flexibles Business Development Director at Coveris, said: “We are extremely pleased with the successful commercial launch of MonoFlex Thermoform 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.”
