Environmentally friendly respiratory masks: sustainable and biobased

In view of the global challenges posed by environmental pollution and the need to make medical protective equipment efficient and sustainable, a team at Ilmenau University of Technology, led by Prof. Florian Puch, has developed an innovative solution: bio-based respiratory masks.

These are not only environmentally friendly, but also offer effective protection against bacteria and potentially viruses. In this interview, Prof. Florian Puch explains the scientific, technological and ecological aspects of this project.

Prof. Puch, what exactly inspired you to develop bio-based respiratory masks?

Prof. Florian Puch: The idea arose from the urgent need to reduce dependence on imports of medical protective masks during the COVID-19 pandemic. Our previous research on antimicrobial plastics gave us a solid foundation. With the support of the Federal Ministry for Economic Affairs and Climate Protection, another department at TU Ilmenau and industrial partners, we then launched the project to develop fully bio-based masks.

Can you go into more detail about the specific materials and their properties?

Puch: The conventional medical and FFP2 masks are largely made of polypropylene, a fossil-based polymer. Our aim was to replace this material with bio-based polymers, which has the advantage that it is made from renewable raw materials and has a lower CO₂ footprint. The central active ingredient in our masks is an extract from pine heartwood, which has natural antimicrobial properties.

How exactly does the filtering effect of these masks work, especially in comparison to conventional FFP2 masks?

Puch: Our masks are designed to provide the same physical filtering effect as FFP2 masks. This is achieved through a similar fiber structure and density that can effectively trap particles. In addition to this physical barrier, the bio-based active ingredient has an antimicrobial effect, which means it can kill or inhibit the growth of bacteria on the surface of the mask.

Can you go into more detail about the antimicrobial effect? How effective are these masks in the fight against bacteria?

Puch: The antimicrobial effect is achieved by the pine heartwood extract. This extract contains natural compounds such as phenols, which have been proven to have a bacteriostatic and bactericidal effect. In our laboratory tests, we have already established that this active ingredient works effectively against various types of bacteria and prevents them from multiplying on the surface of the mask. We are currently conducting further studies to test the antiviral effectiveness of this extract.

What challenges do you see in scaling up production and launching these bio-based masks?

Puch: One of the biggest challenges is scaling up the extraction and integration of the pine heartwood extract into the polymers to ensure consistently high quality and efficacy. In addition, the costs for bio-based polymers are currently higher than for fossil-based polymers, which increases production costs. Another important step is going through the approval process to ensure that the masks meet the legal requirements and can be used safely in the medical field.

How do you see the future role of such sustainable technologies in medical technology?

Puch: I am convinced that sustainable technologies will play an increasingly important role in all areas of medical technology. They not only offer ecological advantages but can also contribute to security of supply and improve people's health. Our research is a step in this direction. We hope that it will inspire further innovation in the industry.