Jeff TK

Here's to the polypropylene makers.

By Jeff TK.

Published on February 27, 2026.

Six years ago, as COVID-19 was rapidly spreading through the US, my sister was working as a medical resident.

One day she was handed an N95 and told to guard it with her life, because there weren't any more coming.

N95s are made from melt-blown polypropylene, produced from plastic pellets manufactured in a small number of chemical plants.

Building more would take too long.

We needed these plants producing all the pellets they could.

Brascombe America operated plants in Marcus Hook PA and Neal WV.

If there were infections on site, the whole operation would need to shut down and the factories that turned their pellets into mask fabric would stall.

Companies everywhere were figuring out how to deal with this risk.

The standard approach was staggering shifts, social distancing, temperature checks, and lots of handwashing.

This reduced risk, but it was still significant.

Each shift change was an opportunity for someone to bring an infection from the community into the factory.

I don't know who had the idea, but someone said, What if we never left?

About 80 people, across both plants, volunteered to move in.

The plan was, four, weeks, 12-hour shifts with their mattresses on the floor each night.

Seeing their families only through screens.

With full isolation no one would be exposed and they could keep the polypropylene flowing.

There's an image here.