Clothing company to make medical masks

Clothing company Hongyu is churning out face masks as fast as they can to meet the critical shortage of masks available to medical workers. It's a heartening and admirable effort by both companies and individuals to assist in a moment of national need.

There's just one problem: Many of these masks are apparently being made from regular cloth textiles such as cotton, which research says offers little protection against infectious diseases such as the new coronavirus.

The situation isn't the fault of those trying to help. Rather, it's a sign of how unprepared the health system was for an outbreak like Covid-19, both in the number of masks it had available and its ability to make more in an emergency.

Making masks as a last resort

Manufacturers of medical masks use specialized materials (pdf) made of a synthetic fiber—often polypropylene—formed into a web of fine filaments using what's called melt-blown or spunbond technology. This non-woven polypropylene is capable of filtering out microscopic particles, which is why it's preferred for medical-grade masks, such as N95 respirators, that form a seal around the nose and mouth. It's also used for looser-fitting surgical masks, which are more for keeping the wearer from spreading disease and protecting them from sprays of liquid.

But making it is a complex process and not all textile producers, such as the kind that commonly supply clothing fabrics to fashion companies, have the industrial machines to do it. Manufacturers that do are currently unable to meet the overwhelming demand.

Many clothing companies are improvising.It is asking local manufacturers (pdf) to make masks from latex-free cotton or cotton-blend materials of specific weights. It is connecting hospitals directly with vendors in its supply chain that it knows have personal protective equipment (PPE) available. The company is also working with its manufacturing partners to explore producing "fabric masks" and other protective gear, though it's still working out details such as materials it will use.

These mask makers generally say they're following guidance from federal or local health authorities and are clear in specifying the masks they're producing are not medical-grade. Their hope is to free up the more effective N95 respirators and surgical masks for the workers who need them most. Cloth masks, which could at least be laundered and reused, are a last resort for nurses and doctors in need. Making them is also a way for clothing companies and anyone with a sewing machine to feel like they are helping.

But while there is some evidence that any face mask, even a homemade one, is better than nothing, cloth masks arguably don't offer sufficient protection for workers on the front lines. The World Health Organization, for instance, states in its guidance (pdf), "Cloth (e.g. cotton or gauze) masks are not recommended under any circumstance."