Manufacturing Process of Masks
Masks have a relatively sophisticated manufacturing process
Surgical masks and N95 respirators are used to prevent the spread of respiratory infections. They are part of the personal protective equipment (PPE) used by health workers and are different from other types of masks used to protect from pollution or dust. Surgical masks are loose fitting and designed to trap sprays and droplets from coughing and sneezing. N95 respirators fit more tightly and can also protect from smaller airborne particles. While N95 respirators are designed to protect the wearer from infections, surgical masks are mostly used to prevent the wearer from disseminating germs and viruses (such as in the case of a surgeon operating on a patient). Surgical masks do not offer full protection against the coronavirus but are recommended for health workers, particularly when both the patient and the worker wear one.
Surgical masks and N95 respirators are both disposable, which explains why they are in such great demand. Their exterior layer may become germ-infested after usage. Furthermore, the mouth's dampness gradually affects their filtering characteristics. Masks are thus only functional for a few hours (four hours for surgical masks and one day for N95 respirators), and altering or reusing them poses a danger of infection. As a result, the objective is to create low-cost, disposable protective gear that can be disposed of and replaced safely. Reusable masks have been demonstrated to increase contamination hazards.
Surgical masks are simple items that are reasonably priced (when they are not in short supply). However, their manufacture necessitates a variety of inputs as well as the assembly of many pieces in a very complex process. The filtering ability of masks is based on a multi-layered non-woven fabric construction. Polypropylene, a polymer made from petroleum oil, is the most often used substance. Polypropylene is "melt-blown" to produce small-diameter fibres in a random pattern that trap small particles. The threads are electrically charged, attracting particles as the air travels through them (electret treatment).
In the face mask factory, Ultrasonic welding is used to join different layers of nonwoven fabric and cloth. An interior layer in contact with the mouth that may absorb moisture (usually white), a filter layer constructed of melt-blown electret non-woven material (as mentioned above), and an outside layer guarding against liquid splashes are the bare minimum (blue, to be distinguished from the inner layer). The inner and outer layers might be composed of cotton or other types of fabric (but they can also be made with non-woven fabrics).
Metal nose strips are used to bend the mask around the bridge of the nose (aluminium, galvanised iron or steel). Simple masks have ties made of the same fabric as the rest of the mask, but more complex masks feature elastic ear loops (made, for example, of nylon spandex) that must be created separately and connected to the filtering layers. These are generally simple procedures that may be performed by most textile enterprises, including people manually running sewing machines for ear loops, for example.
However, a complete manufacturing line that performs all activities and combines many equipment is more efficient. Specialized machines solder the layers together and stamp the masks with nose strips and ear loops, starting with bobbins of non-woven textiles. For the best-performing masks, fully automated manufacturing lines may create up to 1000 masks per minute, while most masks are produced at between 35 and 200 masks per minute. After that, the masks are sterilised before being tested and packaged.
Respirators follow a similar manufacturing method, with two exceptions. To grow stiffer and develop the appropriate shape, one of the layers is first passed through high-temperature and pressure calender rollers. Second, high-efficiency melt-blown electret non-woven material is used to improve filtration, requiring higher-tech machinery and raising manufacturing costs.
Surgical masks and N95 respirators are used to prevent the spread of respiratory infections. They are part of the personal protective equipment (PPE) used by health workers and are different from other types of masks used to protect from pollution or dust. Surgical masks are loose fitting and designed to trap sprays and droplets from coughing and sneezing. N95 respirators fit more tightly and can also protect from smaller airborne particles. While N95 respirators are designed to protect the wearer from infections, surgical masks are mostly used to prevent the wearer from disseminating germs and viruses (such as in the case of a surgeon operating on a patient). Surgical masks do not offer full protection against the coronavirus but are recommended for health workers, particularly when both the patient and the worker wear one.
Surgical masks and N95 respirators are both disposable, which explains why they are in such great demand. Their exterior layer may become germ-infested after usage. Furthermore, the mouth's dampness gradually affects their filtering characteristics. Masks are thus only functional for a few hours (four hours for surgical masks and one day for N95 respirators), and altering or reusing them poses a danger of infection. As a result, the objective is to create low-cost, disposable protective gear that can be disposed of and replaced safely. Reusable masks have been demonstrated to increase contamination hazards.
Surgical masks are simple items that are reasonably priced (when they are not in short supply). However, their manufacture necessitates a variety of inputs as well as the assembly of many pieces in a very complex process. The filtering ability of masks is based on a multi-layered non-woven fabric construction. Polypropylene, a polymer made from petroleum oil, is the most often used substance. Polypropylene is "melt-blown" to produce small-diameter fibres in a random pattern that trap small particles. The threads are electrically charged, attracting particles as the air travels through them (electret treatment).
In the face mask factory, Ultrasonic welding is used to join different layers of nonwoven fabric and cloth. An interior layer in contact with the mouth that may absorb moisture (usually white), a filter layer constructed of melt-blown electret non-woven material (as mentioned above), and an outside layer guarding against liquid splashes are the bare minimum (blue, to be distinguished from the inner layer). The inner and outer layers might be composed of cotton or other types of fabric (but they can also be made with non-woven fabrics).
Metal nose strips are used to bend the mask around the bridge of the nose (aluminium, galvanised iron or steel). Simple masks have ties made of the same fabric as the rest of the mask, but more complex masks feature elastic ear loops (made, for example, of nylon spandex) that must be created separately and connected to the filtering layers. These are generally simple procedures that may be performed by most textile enterprises, including people manually running sewing machines for ear loops, for example.
However, a complete manufacturing line that performs all activities and combines many equipment is more efficient. Specialized machines solder the layers together and stamp the masks with nose strips and ear loops, starting with bobbins of non-woven textiles. For the best-performing masks, fully automated manufacturing lines may create up to 1000 masks per minute, while most masks are produced at between 35 and 200 masks per minute. After that, the masks are sterilised before being tested and packaged.
Respirators follow a similar manufacturing method, with two exceptions. To grow stiffer and develop the appropriate shape, one of the layers is first passed through high-temperature and pressure calender rollers. Second, high-efficiency melt-blown electret non-woven material is used to improve filtration, requiring higher-tech machinery and raising manufacturing costs.
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