Material usage reduced by two-thirds

Medical FFP2 mask with reusable filter holder for sustainable material use. (Image source: Freudenberg Filtration Technologies)

The skin-friendly plastic carrier ensures a good fit and reduced breathing resistance. (Image source: Freudenberg Filtration Technologies)

Medical face masks from Freudenberg Filtration Technologies efficiently filter out aerosols contaminated with viruses and bacteria, thereby protecting human health. Its media competence is also made available to other mask manufacturers by the global filtration specialist and the largest German nonwoven fabric producer. They use Freudenberg filter media for their surgical and FFP masks. A noteworthy, because particularly sustainable example, is the partnership cooperation with Mematec Solutions.

Medical face masks are generally intended for single use and must be disposed of afterward. Mematec Solutions, a manufacturer of pharmaceutical products based in Freiberg, Baden-Württemberg, has developed certified (EN 13685) medical FFP2 masks (EN 149:2009) that reduce this waste volume. The basic idea is not to dispose of the entire mask after use, but only to replace the filter medium.

For this purpose, the nonwoven fabric medium from Freudenberg is stretched and secured onto a reusable filter carrier made of skin-friendly plastic (PET) before use: either with a few simple steps or using an assembly aid. To ensure a good fit, the carrier can be individually adjusted to the shape of the face. After use, it is disinfected and can be reused with ear or head straps. Only the filter medium needs to be disposed of. This avoids waste.

The solution is also ecologically sustainable from a second perspective: since no stabilizing support fabrics like those used in other face masks are needed, the innovative Freudenberg filter medium made of polypropylene—with its highly efficient separation performance—can be comparatively thin and lightweight. Specifically, it consists of only two layers and has a material weight of just 45 grams per square meter. This reduces material consumption by around two-thirds compared to conventional medical face masks.

The low material weight also improves breathing comfort. The airflow resistance is noticeably lower with only two layers than with multilayer media. This is also the goal of the clever design of the Mematec Solutions plastic carrier. It allows almost the entire surface of the filter medium to be traversed by air. This reduces airflow resistance and simultaneously increases separation efficiency compared to conventional masks that sit directly on the skin. The distance of the filter medium from the mouth prevents quick saturation and makes speaking easier. Additionally, the media carriers have lower leakage than typical masks, enhancing protective effectiveness. Not to forget: the Mematec solution prevents fogging of glasses.