Face Mask Teaser

Freudenberg High End Solutions

Behind the Mask

In the midst of a global pandemic, healthcare workers, first responders and many others are working tirelessly to help those affected by the virus while a vaccine is developed. At Freudenberg, employees in different locations worldwide are proud to join this effort by helping bring essential face masks and mask materials to help protect our communities. Meet some of our employees who are helping supply face masks across the world.

Michael Mathews

Michael Mathews, Electrical Engineer:

“It’s a great feeling to be able to contribute to the need of others.”

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Michael Mathews

What is your role at FPM? 

“I joined Freudenberg 9 years ago as an Electrical Engineer. I work on the electrical aspect of projects that involve new equipment installations as well as upgrades of obsolete equipment. On a daily basis, I work on creating drawings in AutoCAD Electrical, procurement of parts for projects, project work specifications for contractors, writing/modifying PLC programs, responding to troubleshooting calls within the plant, and assisting the Maintenance Department.”

What has been the most rewarding aspect of the face mask Project?

“The most reward aspect has been being able to work on the project from the uncrating to the operations of the converting lines. It’s been very rewarding to see the lines come up to speed slowly and to be involved with tuning and improving the performance of the machines.”

What is your role in helping get face masks to the market? 

“When I first came to the face mask facility, it was an older building that needed lots of work to prepare for the arrival of the equipment. I designed the power feed structure and contracted the Electricians that installed it. It now supplies power to all the mask production lines, lighting, HVAC systems, overhead doors, and more throughout the facility.

After the machines arrived, I worked with the team to uncrate, inspect for damage, set in place, align, assemble, and connect the electrical wires. Then we worked together on each machine to commission and tune each function and prepare for turnover to the operations teams. After turnover, I continue to support operations with troubleshooting and problem resolving.”

As a textile supplier, we supply nonwovens to a variety of markets. The actual assembly of end-user face masks is new for FPM. How is supplying necessary PPE during a global pandemic different?

“It’s very rewarding knowing that we are producing face masks that are in high demand right now due to the pandemic. It’s a great feeling to be able to contribute to the need of others.”

 

Michael Mathews, Electrical Engineer USA

Matthew Izzo

Matthew Izzo, Engineering Intern

“I’m extremely blessed to have the opportunity to work on such an impactful project as this is a rare opportunity for someone my age.”

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Matthew Izzo

How long have you been with Freudenberg?

I joined Freudenberg in May 2020 as an Engineering Intern.

What is your role in helping get face masks to the market? 

“As part of the engineering team, I spend most of my day out on the floor working to help debug machines when various issues arise. I also work to continuously improve the machine stability, which includes re-engineering parts, logging changes and creating our ideal machine SPI. I’m also responsible for documenting activities around machine installation such as troubleshooting manuals and work instructions.”

The actual manufacture of end-user ready face masks is new to FPM to help combat the pandemic. As an intern, how did you feel being trusted to work on such a big Project?

“The best thing about my role here in Durham is just that – I have been trusted with a lot of responsibility as a full member of the technical team. It makes me feel valued when operators come to me if an issue arises because they know I can help resolve it. I’m extremely blessed to have the opportunity to work on such an impactful project as this is a rare opportunity for someone my age. I want to do everything I possibly can to validate the trust that has been placed in me and make the most of my time here.”

How has working on the startup of face mask production helped your personal or educational growth?

“During my time here, I’ve learned a lot about the mechanical side of engineering. I continue to learn more every day from the engineers around me - whether something mechanical, electrical or just a better way to do something in general. Another area I’ve experienced growth has been learning how the operations side of a production system runs: how quality systems are implemented, workplace ergonomics as well as how production and engineering work together to achieve a common goal. It has helped me understand the full scope of operational management and how all the individual pieces work in tandem for a successful project.”

 

Matthew Izzo, Engineering Intern, USA

 
Marie Burckel

Marie Burckel, Application Engineer:

“A thing that is so common under normal circumstances, such as sending out a sample with an express courier, was at that time a real challenge...”

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Marie Burckel

What is your role at FPM?

“I am an application engineer, so I work closely with the sales team, R&D and production as well as external partners like finishers and institutes. My task is to make the link with customers to make sure they have the right product that matches their final application.”

As a textile supplier, we supply nonwovens to a variety of markets. How is supplying nonwovens for necessary PPE during a global pandemic different from your typical work? What have you learned?

“We accomplished these challenges thanks to the teamwork between the colleagues who were working in the site and the those who were working in home office. In such a situation, everyone gave the best of themselves to make it possible.”

What is your role in helping get Evolon® to the converters for face mask production?

“I work together with R&D to find the right basis for face masks. I coordinate external testing of our material and translate the test results in data which is useful to the final user and the sales team. Together with marketing, I help with creation of technical data sheets. I am also part of the active technical support team for all companies which convert their standard activities into face mask production activities.”

What has been the most rewarding aspect of the face mask project?

“Participating in the qualification of Evolon® as a suitable base material for community masks at a time when there was a lack of protective masks available has been the most rewarding part.”

What challenges have your overcome within this project? 

“A thing that is so common under normal circumstances, such as sending out a sample with an express courier, was at that time a real challenge as express courier did not pick-up the parcel anymore in ‘cluster areas’”.

Achraf Khedimi

Achraf Khedimi, R&D

“We can beat this crisis by working together and supporting each other.”

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Achraf Khedimi

What is your role in helping get Evolon® to the converters for face mask production?

During the crisis with the lack of face masks and the increasing market needs, we had to postpone our ongoing research and development projects and focus on developing new solutions based on Evolon to meet the urgent and high demand from different governments all over the world. The target was to test and develop a several face mask concepts which could meet the different required filtration and breathability specifications of different countries.

What has been the most rewarding aspect of the face mask project?

We know all advantages of Evolon. But the most rewarding aspect was seeing the product brought into the market in short time for this new application - within days and few weeks -. It was a good feeling that we were able to support in this crisis when people were struggling to find face masks or nonwoven suppliers. It was great to experience that we can beat this crisis by working together and supporting each other. From this angle, our innovating together slogan had a deeper meaning during the crisis.

As a textile supplier, we supply nonwovens to a variety of markets. How is supplying nonwovens for necessary PPE during a global pandemic different from your typical work? 

It is important that Freudenberg, one of nonwovens supplier leaders in the world, has a big variety of markets. This allowed us to use our know-how already our learned in the field of PPE and bring the focus to this specific segment in short time during the crisis.

What has been the most rewarding aspect of the face mask project?

Considering that Colmar area was the first and most hit region in France by the coronavirus, we had to face a bigger charge of work with less resources. We had to overcome our fear and not get disturbed by what was going around and shown in the media. The challenge was to find resources to bring this project into the market, but most importantly also find ways to bring the material to customers by putting new and urgent supply chains in place. This allowed us to support our customers worldwide. 

OUR GLOBAL FACE MASK OPERATIONS

Durham - USA

At our sitein Durham, NC we are manufacturing face masks for consumers and healthcare workers in close cooperation with Freudenberg Household Products North America and other external Partners. 

 

Colmar - France 

The Colmar site has worked closely with outside agencies to certify Evolon® microfilaments for face mask use. The material is now approved for use in community style masks. 

 

Kaiserslautern - Germany 

Our team in Kaiserslautern is manufacturing meltblown and spunbond base materials for use in face masks. The team works closely with Freudenberg Filtration Technologies, who assembles the materials into face masks, and Freudenberg Household Products, who makes them available for consumers in Europe.

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