Borealis and Grabher partnership gives used FFP2 face masks another life

High-quality face masks made in Austria by Grabher contain fully recyclable meltblown polypropylene supplied by Borealis

New collect-and-recycle scheme established by Grabher turns used face masks into value-added products

Partnership is embodiment of the Borealis EverMinds™ spirit of taking action to accelerate the move towards plastics circularity

Borealis, one of the world’s leading providers of advanced and circular polyolefin solutions and a European market leader in base chemicals and fertilizers; and the Grabher Group, a leading manufacturer of high-tech textiles, are accelerating plastics circularity in a partnership that safeguards human health while helping minimise waste. The key component of the high-quality, filtrating face masks produced by Grabher in Austria is made of fully recyclable meltblown polypropylene (PP) supplied by Borealis. To further drive circularity, Grabher has initiated a novel collect-and-recycle scheme for used face masks which turns them into new value-added products such as oil absorption fabrics.

Plastics circularity “made in Austria” through collaboration and innovation

The Vorarlberg, Austria-based Grabher Group is a leading expert in nano-air and micro-liquid filtration and designs smart-textile systems for the manufacture of medical and healthcare products, among others. As the COVID-19 pandemic hit in early 2020, shortages of personal protective equipment (PPE) in Austria were imminent. Grabher acted by becoming the first Austrian company to establish a dedicated face mask assembly facility which included a state-of-the-art meltblown production system for the manufacture of high-quality face masks. These certified masks, including FFP2 filtration respirators, medical masks, and washable community masks, are marketed by Vprotect, a 100%-owned member of the Grabher Group. One essential component of the Vprotect masks – the filter made of densely spaced micron-sized fibres – is made of meltblown PP supplied by Borealis, a material which itself is fully recyclable.

Yet for obvious health reasons, even high-quality and more sustainable face masks are quickly disposed of. Far too many find their way into landfills or even natural environments. To combat the problem of growing volumes of mask waste, Grabher again took action by creating a new return and collection system for used masks in order to recycle them into new, value-added products. The scheme, which is to be rolled out across Austria in the near future, features clearly marked collection boxes into which all types of face masks may be deposited. After sorting, washing, sterilising and drying, the material is used as filler material for cushion and oil absorption applications. Development is currently ongoing to process the masks into granulate which may be turned into absorption fabrics using the meltblown process. These recycled fabrics may be used to absorb oil – for example due to a spill – or other liquids.

“Our partnership with Grabher is the embodiment of EverMinds circular thinking,” claims Vedran Kujundzic, Borealis Vice President Commercial Performance Materials. “Using our fully recyclable meltblown PP to manufacture high-quality masks helps protect human health, and finding a way to use them again protects our planet. Together, Borealis and Grabher have taken yet another step to closing the loop on plastics circularity by maintaining our focus on sustainable solutions which benefit society.”

“We are proud to have responded so quickly to the urgent need for PPE and FFP2 masks, in particular, at the start of the pandemic in Austria,” says Günter Grabher, Managing Director of the Grabher Group. “In the meantime, we are gratified that our collect-and-recycle initiative continues to attract numerous other participants, including OMV, a major food retail group, and several large hospitals. In Borealis, we have found a reliable partner who shares our commitment to both innovation and sustainability, and we look forward to continued collaboration.”

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