The need for fully bio-based facemasks to counter coronavirus outbreaks: A perspective

Area of Science:

• Materials Science
• Biotechnology
• Environmental Science

Background:

• The COVID-19 pandemic highlighted critical shortages of personal protective equipment (PPE), specifically facemasks, increasing infection risks for healthcare providers, essential workers, and the public.
• Conventional facemasks are predominantly manufactured from non-degradable petrochemicals, leading to significant environmental pollution and waste after single use.
• Future pandemic preparedness necessitates a sustainable and reliable supply of essential commodities like facemasks.

Purpose of the Study:

• To develop a sustainable and environmentally benign facemask using wheat gluten biopolymer, a by-product of the cereal industry.
• To create facemasks with filtration efficiency comparable to or exceeding conventional masks while minimizing environmental impact.
• To explore the potential of wheat gluten as a versatile raw material for PPE production.

Main Methods:

• Wheat gluten biopolymer was electrospun into nanofibre membranes and carbonized at over 700°C to create a filter media and reinforcing structure.
• Gluten was processed into cohesive thin films using plasticizers and hot pressing, with lanosol incorporated for fire and microbe resistance (<10 wt%).
• Carbonized mats and gluten-plastic films were combined via thermoforming and bonding, with adapters made from injection-molded gluten.

Main Results:

• A novel facemask design was successfully developed utilizing wheat gluten biopolymer and a carbonized gluten mat as the filter.
• The resulting gluten-based masks demonstrated potential for effective filtration and reinforcement.
• The incorporation of lanosol (<10 wt%) provided the gluten plastics with V-0 rated fire resistance and antimicrobial properties.

Conclusions:

• Wheat gluten biopolymer offers a sustainable and viable alternative for manufacturing facemasks, addressing both supply shortages and environmental concerns.
• The developed facemask design shows promise in reducing the transmission of infectious diseases while promoting eco-friendly product development.
• This approach contributes to circular economy principles by utilizing industrial by-products for essential protective equipment.