Meltblown and spunbond for face masks and respirators

The layers in a mask

Most disposable masks and respirators are built from layers, each with its own job:

• Outer layer: spunbond, which protects the filter layer and gives the mask strength and an even surface.
• Filter layer: one or more layers of meltblown, which capture the particles. This layer decides the filtration performance.
• Inner layer: spunbond against the face, chosen for comfort.
• Respirator designs may add further layers, depending on their shape and construction.

Why the meltblown layer matters

Meltblown is made by extruding molten polymer through microscopic nozzles and stretching it with high-velocity hot air. The fibres are finer than a human hair, under 10 µm in our media, and form a uniform web with high filtration efficiency.

For masks and respirators, the meltblown is given an electrostatic charge. The charged fibres attract and hold fine particles as well as trapping them mechanically, so the layer can filter efficiently while staying open enough to breathe through.

Media for different mask grades

Our meltblown is made as media for N90–N99 and FFP1–FFP3 respirators and for ASTM level 1–3 medical masks. The grade a mask reaches depends on the meltblown itself (its weight, structure and charge) and on the design of the mask, including how many meltblown layers it uses.

Tell us the grade you are making and the standard and test method you will use, and we will make the media to that target. If you are replacing a medium you use now, send its data sheet or a sample.

The grade of the finished mask or respirator is shown by testing the finished product, and approval in your market is the responsibility of the mask maker. Free samples let you test our media in your design before you order.

Choosing the spunbond layers

Outer and inner layers are usually light PP spunbond. Ours is made on Reicofil lines as SS (2-beam) from 10 gsm and SSS (3-beam) from 8 gsm, up to 80 gsm, with an even fibre lay-down for consistent strength across the width. It comes in white or any colour matched to your shade, with hydrophilic, anti-static or other treatments on order. Tell us which side of the mask each layer is for, the weight and the colour.

Rolls for mask machines

Mask machines run narrow rolls from several unwinds at once. We slit meltblown and spunbond to the widths your machine takes. Because both come from our own lines, the filter layer and the cover layers can be ordered from one supplier and shipped together: 5–6 different products can be combined in one 40'HQ container.