Michigan Vinyl Roofing Manufacturer Answers the Call for Critical PPE

As many cities and states begin to reach their peak of COVID-19 cases, the need for personal protective equipment (PPE) isn’t slowing down.

Recognizing the enhanced demand, Duro-Last®, Inc., the world’s largest manufacturer of custom-fabricated, thermoplastic roofing systems, quickly made the decision to switch some of their operations from their typical roofing membranes to medical-grade vinyl isolation gowns and face masks made from vinyl and polyester. With rapid prototyping, they were able to go from prototype to production to delivery in just a week at their Saginaw, Michigan, plant.

On the first day of production, Duro-Last produced about 50 gowns per day on one machine. Now, just a little more than three weeks since they first retooled operations, one machine is capable of making 3,000; paramount considering they’ve received orders for more than 100,000 gowns, which they’re selling at cost.

Why vinyl for PPE?

Vinyl is used in hundreds of medical applications because its unique characteristics meet the health industry’s rigid performance standards. It is especially durable, can be sterilized, and can withstand the harsh cleaning and disinfection requirements between patient visits. And not to mention, it’s liquid-proof.

“A vinyl gown is more impermeable than the standard cloth gown,” said Crint Labrosse, Duro-Last Senior Production Manager. “And while it may be a little bit hotter because the product doesn’t necessarily breathe like a cloth fabric, we’ve received feedback that medical professionals prefer plastic PPE because they feel it protects them better.”

Another unique benefit of vinyl is its recyclability. After disinfecting the PPE, it could be ground up and reused in another product. Duro-Last already has a takeback program for its roofing materials, and Labrosse mentioned they would consider a takeback program for the PPE gowns in the future.

The need is nationwide.

Duro-Last had originally planned to focus their efforts locally, but the need has been too great. While many of the products they have manufactured so far have been fulfilling orders from Michigan hospitals, they will also be shipping products to healthcare systems out of state. Additionally, with plants throughout the country, their facilities in Mississippi, Oregon, Texas, and Iowa will join the battle, producing PPE for their local hospital systems.

Duro-Last CEO Tom Saeli stressed that they began manufacturing these medical supplies to save lives, and he hopes that their story can inspire other manufacturers that may also have the means to adapt and shift their operations to do the same.

“Our country is full of tremendously smart, entrepreneurial people who can bring timely solutions to this unprecedented need,” Saeli said. “The need is real, and I believe it’s our obligation to act now. If the efforts of our team inspire just one other company to join this fight, it will be worth it.”

Find more about PVC/vinyl on the frontlines for COVID-19 relief here.