Development of a reusable low-cost facemask with a recycled hydrophobic layer for preventive health care

The current work focuses on designing a low-cost, reusable, and highly efficient facemask for protection from respiratory droplets that cause COVID-19, other infection-causing organisms, and dust allergies. Several masks available in the market are single-use that would choke the environment through plastic pollution or are expensive for the commoner to afford. In the present study, the facemask incorporates a waste-derived polyethylene terephthalate (PET) layer and a non-woven polypropylene (PP) layer sandwiched between two tightly woven cotton layers. Combining these layers provides comfort and breathability, besides high bacterial and particulate filtration efficiency. Moreover, the unique PET layer provides mechanical strength and a 3D shape that enables hindrance-free speaking and prevents spectacle fogging. Compared to commercial N95 masks, the developed mask can be reused up to 30 washes and recycled with zero waste discharge ensuing green technology. Moreover, the mask was produced at an affordable cost of Rs. 17 (0.22 USD), including labor charges, and sold at a 100% profit margin @ Rs.35 (0.45 USD) per unit. Further, the mask was certified by neutral testing agencies and provided to a population of more than 6 lakhs, thus significantly contributing to the mitigation of COVID-19. SUPPLEMENTARY INFORMATION: The online version contains supplementary material available at 10.1007/s11356-022-24807-7.