Larger Droplets Do Not Contain More Virus Than Small Droplets

Berry Delivers Record Earnings in Third Quarter

Previous Alerts Show Expansion of Berry Meltblown Capacity

Berry is Expanding Meltblown Capacity - April 13

Berry Switching to Mask Media at Plants in the U.S. and China - April 13

Berry Global has New Material for Surgical Masks - April 21

Berry Building 400 tpy Meltblown Facility in South America - May 28

Berry Installing New Meltblown Line in Berlin - May 14

Berry Global to Supply Medicom with Media for Hundreds of Millions of Face Masks per Year

Seventy-five Percent of Children at Georgia Camp Test Positive

Chinese Mask Prices are Down Substantially from Peak

 

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Larger Droplets Do Not Contain More Virus Than Small Droplets

This is the opinion of Linsey Marr in a NY Times Op-ed. It might seem logical, or make intuitive sense, that larger droplets would contain more virus than do smaller aerosols — but they don’t.

A paper published this week by The Lancet Respiratory Medicine that analyzed the aerosols produced by the coughs and exhaled breaths of patients with various respiratory infections found “a predominance of pathogens in small particles” (under 5 microns). “There is no evidence,” the study also concluded, “that some pathogens are carried only in large droplets.”

A recent preprint (not peer reviewed) by researchers at the University of Nebraska Medical Center found that viral samples retrieved from aerosols emitted by Covid-19 patients were infectious.

Some scientists have argued that just because aerosols can contain SARS-CoV-2 does not in itself prove that they can cause an infection and that if SARS-CoV-2 were primarily spread by aerosols, there would be more evidence of long-range transmission.

I agree that long-range transmission by aerosols probably is not significant, but I believe that, taken together, much of the evidence gathered to date suggests that close-range transmission by aerosols is significant — possibly very significant, and certainly more significant than direct droplet spray.

When it comes to masks, size does matter.

The gold standard is a N95 or a KN95 respirator, which, if properly fitted, filters out and prevents the wearer from breathing in at least 95 percent of small aerosols.

The efficacy of surgical masks against aerosols varies widely.

One study from 2013 found that surgical masks reduced exposure to flu viruses by between 10 percent and 98 percent (depending on the mask’s design).

A recent paper found that surgical masks can completely block seasonal coronaviruses from getting into the air.

To my knowledge, no similar study has been conducted for SARS-CoV-2 yet, but these findings might apply to this virus as well since it is similar to seasonal coronaviruses in size and structure.

My lab has been testing cloth masks on a mannequin, sucking in air through its mouth at a realistic rate. We found that even a bandanna loosely tied over its mouth and nose blocked half or more of aerosols larger than 2 microns from entering the mannequin.

We also found that especially with very small aerosols — smaller than 1 micron — it is more effective to use a softer fabric (which is easier to fit tightly over the face) than a stiffer fabric (which, even if it is a better filter, tends to sit more awkwardly, creating gaps).

It’s not clear just how much this coronavirus is transmitted by aerosols as opposed to droplets or via contact with contaminated surfaces. Then again, we still don’t know the answer to that question even for the flu, which has been studied for decades.

But by now we do know this much: Aerosols matter in the transmission of Covid-19 — and probably even more so than we have yet been able to prove.

Linsey C. Marr is the Charles P. Lunsford Professor of Civil and Environmental Engineering at Virginia Tech. the full op ed  can be viewed at https://www.nytimes.com/2020/07/30/opinion/coronavirus-aerosols.html

Berry Delivers Record Earnings in Third Quarter

Berry’s Chairman and CEO, Tom Salmon said, “Through our employees’ relentless effort and dedication, along with our diverse, stable portfolio, we were able to deliver record earnings for any quarter in the Company’s history. We have made progress and remain focused on our top three financial objectives of improving our strong balance sheet, organically growing our businesses, and integrating the RPC acquisition as demonstrated in this recently completed quarter.

“I am happy to report we generated a June quarterly record for net sales of over $2.9 billion, up 50 percent compared to the prior year quarter. Operating income increased 61 percent to $347 million while Operating EBITDA was a record for any quarter in the Company’s history at $581 million. Our adjusted earnings per share increased 69 percent to $1.52, and we reported a significant improvement in quarterly free cash flow, bringing our four quarters ended free cash flow to over $1 billion.

“For the June 2020 quarter, overall organic volumes for our legacy Berry businesses were up 2 percent. Our Health, Hygiene & Specialties segment recorded strong volume growth of 14 percent related to our recent investments, our targeted market approach, along with COVID-19 related benefits in our healthcare portfolio. Excluding COVID-19 benefits, we believe the business delivered high-single digit growth in the quarter. We are very proud of our teams in achieving their objectives of delivering profitable and sustainable growth. Our Consumer Packaging-North American business recorded flat volume for the quarter with strength in healthcare, household cleaning and grocery offset by softness in food service and industrial markets. We remain encouraged by the momentum of the Division with a continued growing revenue pipeline. Our Engineered Materials business saw volume declines of 8 percent in the quarter driven by headwinds related to COVID-19. Many of the products in that business are sold through distribution to schools, offices, or restaurants, to name a few end markets, which saw more contracted demand than our more consumer facing businesses. Excluding COVID-19, we believe the business would have grown low-single digits.

“Our financial profile remains solid as we have a strong liquidity position with over $900 million of cash at the end of the quarter as well as an undrawn $850 million asset-based line of credit representing nearly $1.8 billion of liquidity. Also, we have no financial maintenance covenants or near-term debt maturities.”

June 2020 Quarter Results

While certain markets have been impacted by COVID-19 in a variety of ways, like restrictions on daily activities and changes in consumer demand, we are fortunate to have such a diversified portfolio with strong, stable end markets. As such, we are pleased to report that we are increasing our fiscal year 2020 free cash flow to $830 million, which includes $1.45 billion of cash flow from operations partially offset by capital expenditures of $620 million. Cash taxes are expected to be $170 million, and cash interest costs are projected at $430 million. Additionally, we expect working capital, restructuring and other costs to be $50 million.

We still believe approximately 65 percent of our portfolio is advantaged to neutral with about 35 percent negatively impacted related to COVID-19. Specifically, on volumes, we anticipate our Health, Hygiene & Specialties segment to produce low double-digit growth. Our Consumer Packaging - North American business, we believe, will experience low-single digit volume growth as headwinds in the foodservice space moderate along with continued solid demand in hygiene and grocery markets. We believe both our Consumer Packaging - International and Engineered Material businesses will experience low-single digit and mid-single digit volume declines in our fiscal fourth quarter, respectively, related to the weakness from the impact of COVID-19. As COVID-19 headwinds subside we would expect the businesses to ultimately achieve low-single digit volume growth.


Previous Alerts Show Expansion of Berry Meltblown Capacity

Here is a table showing Berry expansions of meltblowns and composites for  masks

 

Berry is Expanding Meltblown Capacity - April 13

Berry Global Group  is adding a fabric machine to its Biesheim, France factory. The machine will spin out 720 metric tons of filtration fabric per year. That is enough for 480 million masks, which is good, but it would be better for U.S. hospitals if there were five more installations in the works and all were in the U.S.

How quickly can more machines be built, and who will pay for those machines? There isn’t much discussion of that topic in White House announcements. This is a tricky business. A production line for nonwoven fabric can run to $50 million. If it is destined to sit idle at the end of the pandemic, it’s not a good investment.

Both Berry and 3M are making heroic efforts to redirect their factories to medical needs. In normal times 3M’s mask output is aimed primarily at the industrial and construction markets; now it’s almost all going into the virus fight. Berry had originally planned its new Biesheim machinery to supply manufacturers of air filters; now the fabric will be made for masks. Berry also announced this week that it would use factories in Indiana and Kentucky to make face shields, a business it was not in before. They’ll crank out 300,000 shields a month.

Curt Begle, who oversees the $2.5 billion (sales) medical and specialties division of Berry, says the assembly time for the Biesheim equipment was accelerated from five months to three and a half, and the additional production line will be producing fabric by the end of June.

The centerpiece of the Biesheim operation is a “meltblown” machine engineered by the German firm Reifenhäuser Reicofil.

Biesheim’s filtration fabric will supply the European market. Berry has converted a pilot fabric line in Virginia to making the filter layer, but its output is only enough for 150 million masks a year. The company has a big plant in China, but the output of that plant goes to Chinese mask factories.

https://www.forbes.com/sites/baldwin/2020/04/03/480-million-masks-for-europe-where-are-ours/#2f4144824d85

Berry Switching to Mask Media at Plants in the U.S. and China - April 13

Berry has persuaded customers in the bedding and furniture industries to defer orders so that it can focus on medical needs. The company pivoted a new $70 million factory investment in Nanhai, China, from supplying electronics companies to supplying mask makers. It is about to turn a test-run operation in Waynesboro, Virginia, into a production line that would produce enough filtering fabric for 400,000 masks a day. It has engineers tinkering with similar equipment in Old Hickory, Tennessee, to get the same result. It has resurrected a decommissioned fabric line. “We’re leaving no stone unturned,” says Thomas Salmon, Berry’s chief executive.

Berry has six U.S. plants that make either fabrics or films that go into masks, protective gowns, surgical drapes and antiseptic wipes. All these are relevant to the current war effort, but there is one weapon against coronavirus that is in crucially short supply: meltblown polypropylene.

Berry has two meltblown lines at a Biesheim, France, factory, but all of their output is going into the European market. Its Nanhai factory cranks out meltblown, but the Chinese market has until recently swallowed all of it.

What about buying another meltblown machine to be installed in the U.S.? It would be a long time coming, says Salmon. He points to a $50 million line Berry recently added in Mooresville, North Carolina, for the production of fabric for disinfectant wipes. That project started long before the virus emerged. It took a year.

Projects that take a year in normal times take less in an emergency. There are two big European manufacturers of machinery to make nonwoven plastic fabrics: Reifenhäuser Reicofil, a family-owned firm in Troisdorf, Germany, and Oerlikon, a publicly traded company near Zurich. A few days ago Reifenhäuser announced that it cut the lead time for a meltblown machine to three and a half months.

Output arriving in the summer comes too late to cure the immediate shortage of protective gear in New York. But it could address mask needs in other states, or help with a second wave of the epidemic, if that occurs. A machine blowing 550 tons of poly per year would produce the fabric for 1.8 million masks a day.

Berry Global has New Material for Surgical Masks - April 21

Berry Global will increase production of face mask materials. The initiatives include additional capacity for the production of face mask materials in North America and a new material for face masks in Europe. With demand outpacing current supply for face mask filter media, the product development team at Berry has responded to deliver innovative solutions in a matter of weeks to support the demand. These solutions include pivoting existing manufacturing assets and creating alternative materials for face masks.

Berry has expanded its proprietary Meltex platform to add meltblown capacity in Waynesboro, VA. The line will make meltblown materials which will ultimately be used in surgical-grade face masks along with N95 and N99 respirators. This added capacity will support the manufacturing of approximately 200 million face masks annually.

Berry is also launching an extension to its Synergex range of products, Synergex ONE, a new media for face mask applications. Developed to initially meet the new face mask categories for general population, the aim is to quickly bring the media up to EN 14683:2019 standards for surgical masks. The newly introduced Synergex ONE provides a multilayer nonwoven composite product in a single sheet, as an alternative to traditional face mask layer structures. This new material will be manufactured in Europe and serve the European market and is available immediately.

“This was something that was of paramount importance in the short term development,” says Cedric Ballay EVP & GM for Europe in Health, Hygiene, and Specialties for Berry. “Given the array of materials currently being offered to the market, we are proud to offer an alternative solution to the traditional charged meltblown. We are now continuing to push on with the development to be able to pass BFE Type I and Type II testing with this media.”

Features are

         Multi-layer composite material – no lamination needed

         Filtration core of unique meltblown technology

         Suitable for general use

 
Berry Building 400 tpy Meltblown Facility in South America - May 28

 Berry announced the capital investment in its global meltblown nonwoven fabric capacity for South America. This investment further strengthens the Company’s global reach and position as the leading nonwovens manufacturer. This line is Berry’s first meltblown asset, based on its Meltex™ technology, to be located in South America and continues to support the demand for health and wellness products.

“We are pleased to present this state-of-the-art meltblown capacity to the South American market. As customers prepare for future outbreaks or protection demands, we will be ready to serve” said Daniel Guerrero, EVP & GM for Latin America in Health, Hygiene, and Specialties at Berry.

With continued demand for face masks globally, Berry has been working closely with customers to help ensure production and supply. The investment will bring more than 400 metric tons of Meltex™ meltblown nonwoven material to the region, which will enable production of more than 500 million surgical-grade masks per year.

The new asset will be operational in the March 2021 quarter, will be placed at an existing Berry production facility in South America, and will focus on the production of materials for ASTM L2, L3, and N95 masks. The new line will be upgraded with Berry’s patented charging technology post installation.

Berry Installing New Meltblown Line in Berlin - May 14

Berry Global Group, Inc. announced the continued expansion of its global Meltex™ meltblown capacity, with the addition of another asset to support the growing global face mask demand.

This announcement comes as demand surges due to COVID-19 and the increased need for nonwoven protection materials. The new asset is expected to be operational in October 2020 and will be placed in Europe at Berry’s existing production facility in Berlin, Germany and will incorporate Berry’s patented charging technology post installation. The new line will focus on the production of highly efficient filter material for premium FFP2 (N95) and FFP3 (N99) grade filter media.

“We are now beginning to see the localization of varying forms of equipment that produce materials for PPE, as countries and governments look to be able to react with speed to any future outbreaks,” said Cedric Ballay EVP & GM for Europe in Health, Hygiene, and Specialties at Berry. “We continue to provide timely solutions to those looking for assistance fighting the spread of COVID-19.”

As the largest manufacturer of nonwoven fabrics, Berry makes materials for the world’s leading and emerging brands. These products range in use from materials for face masks, respirators and protective healthcare apparel to packaging, many of which have been deemed essential in the efforts to fight the spread of COVID-19.

Berry Global to Supply Medicom with Media for Hundreds of Millions of Face Masks per Year

Berry Global is collaborating with The Medicom Group, (Medicom), to design the manufacturing solution and guarantee the supply of nonwoven fabric intended for use in producing hundreds of millions of face masks annually as part of Medicom’s agreement with the British Government. Medicom is one of the world’s leading manufacturers of medical and respiratory masks.

To do so, Berry is investing in a new state-of-the-art meltblown nonwovens line, to be outfitted with its proprietary charging technology, at one of its U.K. based facilities to increase capacity of material necessary in the production of European-standard Type IIR and N99-equivalent FFP3 masks. The masks will be manufactured and sold under Medicom’s European Kolmi brand.

The British Government has enabled these investments through a long-term contractual commitment. The agreement confirmed support for Medicom’s new U.K.-based production facility, which is scheduled to open later this summer. This move highlights the focus governments are placing on securing a supply chain that helps ensure a local supply of personal protective equipment.

“Berry has deep roots in the U.K. We are pleased to support Medicom as they open their new facility and help advance safety and protection in the region well beyond the COVID-19 pandemic,” says Curt Begle, president of Berry’s Health, Hygiene, and Specialties Division.

Seventy-five Percent of Children at Georgia Camp Test Positive

A new report suggests children of all ages are susceptible to coronavirus infections and may also spread it to others — a finding likely to intensify an already fraught discussion about the risks of sending children back to school this fall.

The report, released Friday by the Centers for Disease Control and Prevention, details an outbreak at a sleep-away camp in Georgia last month in which 260 children and staff — more than three-quarters of the 344 tested — contracted the virus less than a week after spending time together in close quarters. The children had a median age of 12. The camp had required all 597 campers and staff to provide documentation they had tested negative for the virus before coming. Staff were required to wear masks, but children were not.

Of those who were tested and came up positive, 231 were aged 17 or younger; the remaining 29 were adults. Data about symptoms was available for only 136 patients: About a quarter, or 36 people, reported no symptoms; A hundred children and staff (74 percent) reported symptoms, including fever (65 percent), headache (61 percent) and sore throat (46 percent).

While similar clusters have occurred around funerals, weddings, teenage parties and adult gatherings throughout the covid-19 pandemic, few super-spreading events have been documented among children.

“To me, this is a significant weight added to the side of the scale that says close the schools,” said Andrew Noymer, an epidemiologist at the University of California-Irvine. “At some places, that might tip the balance. You’re not adding one of those 1,000-ton anvils in the cartoons, but it’s solid evidence to suggest we should be extremely cautious about opening schools."

 

Chinese Mask Prices are Down Substantially from Peak

 

The coronavirus-related mask manufacturing bubble in the first half of 2020 is rapidly bursting, according to an article attracting 35 million views on Weibo last week. According to interviewed manufacturers, producer prices for the ubiquitous face mask have fallen by up to 90% from a high of 1.6 yuan ($0.22) in March, while export prices have dropped from $0.65 to $0.17-0.20.

As China and the rest of the world scrambled to buy medical-quality masks, protective equipment and ventilators at the start of 2020, Chinese manufacturers switched production and these sectors swelled with excess capacity. According to an article published by the business news site 21jingji.com, demand for filtration fabric called meltblown material initially rocketed and investment in mask production equipment flooded into the sector. But in a few short months, manufacturers have discovered that demand can also recede.

According to a producer from Hubei interviewed by 21jingji.com, “At the peak in March, masks cost 1.6 yuan each wholesale, and we were making profit of up to 0.5 yuan apiece.” The producer will not quit on the sector, he says, as raw materials have fallen in cost even faster, which means he still makes comfortable profit margins. He believes raw materials are one twentieth their peak price.

One export manager told 21jingji.com his company entered the mask business at its hottest and spent a lot of money on export certification. While export prices have fallen since, orders are stable, and overseas prospects have not yet cooled.

Switching from plastics to filtration material and mask production has been an important lesson in the cost of business transition for a large swathe of manufacturers in the country.

Weibo users responded to the topic by noting manufacturers have been making good money by switching to high grade medical masks. “No wonder regular masks are such poor quality now. . . As soon as the last one was finished, the company packed up and transferred out of there.”

Mask buyers in China believe the money was made off their backs, with one user asking, “1.6 yuan? Are you sure? 4 to 5 yuan was the cheapest I could buy a mask for.” Export prices were also the subject of discussion with one commentator in the U.S. writing: “Home Depot is selling masks now for $0.60 each in the most eye-catching spot in the store. I’ve seen companies buy them for their staff, and buy a lot, which means Home Depot must be making plenty of money.”

 In Ohio County, including Wheeling WA,  Schools officials are touting recent upgrades at several schools as an effective way in protecting students and staff from COVID-19, and those same improvements are being made throughout the system.

Needlepoint bipolar ionization units installed in 2019 at Elm Grove Elementary School, Middle Creek Elementary School and Wheeling Park High School have been found to be effective in combating the virus that resulted in a worldwide pandemic, according to a study by Innovative Bioanalysis.

Ohio County Schools officials were made aware of the findings by CMTA Energy Solutions Project Manager Jonathan Gasser. Ohio County Schools have partnered with CMTA in work taking place throughout the school system as part of the more than $40 million bond initiative approved by Ohio County voters in 2018.

“Needlepoint bipolar ionization promotes indoor air quality, and it adds an additional layer of protection,” Gasser said. “These units are effective against COVID-19. The science on past corona viruses revealed that this technology was effective at rendering it harmless at a rate of 99 percent. The information from Innovative Bioanalysis found that 99.4 percent of the specific COVID-19 virus was inactivated after 30 minutes, as a result of needlepoint bipolar ionization. Scientists may debate the exact details, but it has been shown many times that the ionization units work against coronaviruses and therefore works against COVID-19.”

Ohio County Schools Operations Administrator David Crumm said needlepoint bipolar ionization is now being installed at Triadelphia Middle School, Steenrod Elementary School and West Liberty Elementary School.

The needlepoint biopolar ionization will also be installed at Warwood School and Woodsdale Elementary School. Crumm is currently in discussions with Gasser about the possibility of adding the needlepoint bipolar ionization to the schools that do not have the system in place.