Excellence in Demand: The importance of nonwoven melt-blown material in N95 mask manufacturing

At the beginning of 2020, the production of N95 masks in the United States alone was around 45 million units. When COVID-19 hit, manufacturers worked feverishly to meet elevated demand for critical personal protective equipment (PPE), with production estimates at the end of the year nearing 180 million units.


Mask production rose exponentially to an expected 180 million units by the end of 2020.


It quickly became apparent that the novel coronavirus would only be stopped by a vaccine, and several pharma companies jumped into research and development. Typically, however, it takes years for a successful vaccine to be approved. Prior to the recently-released COVID-19 vaccines by Pfizer, Johnson & Johnson, and Moderna, the record holder for the fastest vaccine was the Mumps vaccine in 1967, which took 4 years to be developed.


Even with the unprecedented speeds the COVID-19 vaccine has been released, experts expect the disease to take an extended toll.


A busy 2021

“Pandemic fatigue” has become a real thing, and combined with a new year, frustration over continued restrictions, and the beginning of immunization rollouts, individuals and communities everywhere are starting to test the boundaries of current coronavirus precautions. But medical experts caution that the disease isn’t yet eradicated, and that’s why we need to remain vigilant.


Superior components turn into superior products

Not every mask is equal. You’ve read articles and listened to news updates outlining the differences in PPE. But what are the differences in how masks are made? How do we ensure Green Resources Consulting is delivering the best, most effective products to our customers?


By sourcing the highest-quality, most durable materials that adhere to the strictest testing standards, we are able to produce reliable products frontline workers and caregivers can trust.


About the materials

There are two critical raw material components needed to manufacture PPE face masks:


  • Spun-bond polypropylene material

  • Melt-blown material


Our N95 masks & surgical masks

Combined with activated bamboo charcoal that delivers superior filtration, Green Resources Consulting made the conscious decision to use layers of melt-blown nonwoven material combined with layers of spun-bond material in our mask manufacturing process. This combination allows for the ultimate in filtration, protection, fit, comfort, and durability.


Our N95 mask has a total of FIVE layers of high-quality protection. Three layers of melt-blown material are situated between an outer and inner layer of spun-bond material, for a total of FIVE protective layers. (Compared with standard masks that commonly have only three layers, the GRC N95 mask delivers much more filtration and protection.)


The GRC surgical mask is constructed of four pleated layers, using similar processes and the same high-quality materials.


About melt-blown nonwoven material

Melt-blown material is made by layering fibers and then heat bonding them into a weblike fabric that captures particles before they can pass through. Visualize a tightly woven spiderweb. The construction of melt-blown fabric is similar, making is nearly impossible for even the smallest particles to find their way through the maze of bonded fibers.


Also known as melt-blown extrusion, this process produces a nonwoven fabric that serves as a moisture barrier—protecting both patients and caregivers from liquids that may be expelled through coughing, sneezing, or even talking.


Equipped with electrostatic properties, melt-blown material causes electrostatic adsorption, trapping particles instead of allowing them to pass through to the mask wearer.


Adsorption, what’s that?



Melt-blown material—used in GRCIT masks—captures up to 95% of particles and pathogens from the air and prevents them from passing through to mask wearers!


About spun-bond material

Spun-bond material has a soft fabric-like feel and is recommended as a PPE material because of its washability, durability, breathability, and comfort. Intended to serve as a moisture barrier and repel fluids, its hydrophobic characteristics make it ideal for medical settings.


Every day, Green Resources customers are breathing the benefits of the highest quality materials, including melt-blown and spun-bond nonwoven materials and activated bamboo carbon. Our focus on sustainable, eco-friendly solutions will never waver, and we’re happy to deliver rigorously tested, exceptional products that protect our neighbors and our planet.


Ready to discover more about Green Resources and our planet-conscious PPE? Let’s talk about delivering the best protective equipment for you and your team while promoting eco-healthy agroforestry and reaping the benefits of sustainable bamboo!


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