Coveris Launches MonoFlex Thermoform: Recyclable Mono-Material Films Redefine Food Packaging
Coveris, one of Europe's leading packaging manufacturers, has unveiled MonoFlex Thermoform — a breakthrough in recyclable thermoforming film technology that directly replaces non-recyclable mixed-material substrates. The announcement, made in May 2025, marks a significant milestone in the flexible packaging industry's march toward full circularity, as converters and brand owners scramble to meet the EU's Packaging and Packaging Waste Regulation (PPWR) deadline of 2030.
Thermoforming applications — widely used for trays, cups, and blister packs in food sectors — have historically relied on multi-layer laminates combining nylon (PA), polyethylene (PE), and other polymers to achieve the necessary barrier properties, puncture resistance, and sealing performance. These mixed-material structures are virtually impossible to recycle through existing mechanical recycling streams. Coveris' MonoFlex Thermoform changes that equation by delivering the same performance in a fully recyclable, single-polymer format.
Technical Specifications: Nylon-Free PE and PP Films with Advanced EVOH Barrier
MonoFlex Thermoform films are produced from high-performance polyethylene (PE) or polypropylene (PP) monomaterials and are fully nylon-free — a critical design choice that enables seamless integration into existing recycling infrastructure. Unlike conventional thermoforming films that embed nylon layers for strength and oxygen barrier, MonoFlex Thermoform leverages advanced co-extrusion technology and proprietary EVOH (ethylene vinyl alcohol) barrier layers to achieve comparable or superior product protection.
The EVOH barrier delivers excellent oxygen transmission rate (OTR) performance, preserving product freshness and extending shelf life across a range of sensitive food applications. Combined with strong puncture resistance validated through Coveris' Pack Innovation Centre testing protocols, the film performs reliably through packaging, distribution, and retail handling.
Manufactured at Coveris facilities in Germany and the United Kingdom, MonoFlex Thermoform can be produced as single-substrate co-extruded or laminated films, depending on specific product application and print requirements. This manufacturing flexibility allows converters to tailor the structure without switching suppliers or compromising on downstream performance.
Applications Across Bakery, Meat, Fish, Poultry, and Dairy Sectors
The new films are designed for a broad range of food packaging applications:
- Bakery products — bread, pastries, cakes, and biscuits requiring moisture control and aroma preservation
- Meat and poultry — fresh and processed meats demanding high oxygen barrier and puncture resistance
- Fish and seafood — chilled and frozen fish products sensitive to oxidation and odor transfer
- Dairy products — cheese, yogurt cups, and dairy-based desserts requiring controlled atmosphere packaging
This versatility positions MonoFlex Thermoform as a drop-in replacement across a significant portion of the European thermoformed food packaging market, which accounts for an estimated 30% of all rigid and semi-rigid food packaging by volume.
Seamless Transition for Converters: Wide Operating Window and Print Compatibility
One of the most practical advantages of MonoFlex Thermoform is its wide operating window, which allows converters to maintain existing packing speeds without costly equipment modifications. The material has been engineered to perform on standard thermoforming lines, minimizing the technical barriers that often delay adoption of new sustainable substrates.
For brands requiring on-pack communication, the top film is available with conventional and HD flexographic or rotogravure printing, including matt, gloss, and tactile lacquer finishing options. Even unprinted films can be paired with Coveris' labelling solutions as a secondary process, offering multiple paths to achieve brand presence and regulatory compliance labeling.
The Bigger Picture: Mono-Material Momentum and the PPWR 2030 Countdown
The launch of MonoFlex Thermoform arrives at a decisive moment for the flexible packaging industry. The EU PPWR mandates that all packaging placed on the European market must be recyclable at scale by 2030, with interim targets beginning as early as 2028. For thermoforming applications — where mixed-material laminates have been the default choice for decades — this represents a fundamental redesign challenge affecting thousands of product lines.
According to Packaging Market Insights, the global sustainable flexible packaging market was valued at USD 198.4 billion in 2025 and is projected to reach USD 382.6 billion by 2034, growing at a CAGR of 7.1%. Mono-material packaging represents one of the fastest-growing sub-segments, driven by regulatory pressure and brand owner commitments to circular economy targets.
Christian Kolarik, CEO of Coveris, underscored the strategic importance of the launch: "MonoFlex Thermoform is a significant development from the Coveris Group. Manufactured across multiple locations supporting our vision for No Waste, our monomaterial, recyclable films are a direct replacement for non-recyclable alternatives. This enables a significant amount of plastic packaging to be captured through recycling processes, achieving environmental benefits including carbon footprint reduction."
Coveris is uniquely positioned to support this transition through its vertically integrated model — spanning film development, material science, extrusion, print, conversion, shelf-life enhancement, and machine validation — giving converters and brand owners a single partner for the full packaging development cycle.
Industry Implications: What MonoFlex Thermoform Means for Brand Owners
For brand owners and retailers operating in the European market, the availability of recyclable thermoforming films addresses a growing compliance gap. Many major supermarket chains — including Tesco, Carrefour, Aldi, and Lidl — have independently committed to 100% recyclable, reusable, or compostable own-brand packaging by 2025-2027, well ahead of the PPWR's 2030 deadline. These voluntary commitments have created urgent demand for packaging solutions that deliver both recyclability and the barrier protection required for fresh and processed foods.
The economic case is equally compelling. Under the EU's Extended Producer Responsibility (EPR) schemes, packaging that is not recyclable incurs significantly higher fees — in some member states, non-recyclable packaging attracts fees up to five times higher than recyclable alternatives. Switching to mono-material solutions like MonoFlex Thermoform can therefore deliver direct cost savings while strengthening brand sustainability credentials in an increasingly eco-conscious consumer landscape.
Furthermore, the mono-material approach aligns with the Ellen MacArthur Foundation's New Plastics Economy Global Commitment, which has been signed by over 500 organizations representing 20% of all plastic packaging produced globally. Signatories commit to making 100% of their plastic packaging reusable, recyclable, or compostable — a target that thermoforming applications must now meet.
Sinoflex Packaging: Your Partner in Sustainable Flexible Packaging Solutions
At Zhucheng Zhongjun Packaging Co., Ltd. (Sinoflex Packaging), we recognize that innovations like MonoFlex Thermoform signal a permanent shift in how the flexible packaging industry approaches material design. As global regulations tighten and consumer expectations for sustainability rise, packaging converters and brand owners need partners who combine technical expertise with reliable manufacturing capabilities.
With a 17,685 m² production base — including a 10,248 m² dust-free cleanroom — and BRC and ISO 9001:2015 certifications, Sinoflex Packaging delivers high-quality flexible packaging solutions to over 1,000 clients across 50+ countries. Our product portfolio covers stand-up pouches, flat bottom bags, spout pouches, aluminum foil bags, roll stock films, and biodegradable packaging options, all manufactured on intelligent automated production lines.
Whether you are exploring monomaterial transitions, launching new products in European markets requiring PPWR-compliant packaging, or seeking a reliable OEM/ODM partner with 20+ years of manufacturing experience, Sinoflex Packaging is ready to support your journey. Contact us today at www.sinoflexpack.com for free samples and custom packaging consultations.