In Just 6 Days Duro-Last Switched from Manufacturing Roofing Systems to Producing PPE

By Lauren White, RCS Reporter.

Roofing materials protect buildings and healthcare workers on the frontline of the coronavirus pandemic.

The world’s largest manufacturer of custom-fabricated, thermoplastic roofing systems, Duro-Last Roofing, Inc., has switched gears to start producing personal protective equipment (PPE) for healthcare workers on the frontline of the current coronavirus pandemic.  This transition to producing isolation gowns and non-surgical face masks took just six days.

Duro-Last responded to Michigan Governor Gretchen Whitmer’s announcement of the dire need for PPE.  “The thought of a stockpile is a dream right now because we’re just trying to get our hands on every mask, every N95, every gown and glove we can get.”  She explained that some hospitals are left with only a few days of PPE while others are finding ways to conserve as much as possible.  

Based in Saginaw, Michigan, the gowns and masks will be produced at Duro-Last’s various manufacturing plants throughout the United States in Oregon, Mississippi, Iowa, Texas and Massachusetts.

Mike Tracey, the Vice President of Operations, showed ABC12 the gown, sharing, “What it does is offer full protection front to back...It’s made of flexible PVC film and repels liquids.”  This is an especially important feature when fighting the coronavirus since this pathogen is able to travel through the air via respiratory droplets produced when a sick person breathes, talks, coughs, or sneezes.  The face masks, made from polyester and PVC, are washable and reusable.

“We can make film at a rapid rate.  That’s the base product that we use in our roofing,” Tracey said.  The gowns start with the PVC film and are then pulled across the fabric cutting machine to be cut into the desired shape.  The fabric cutter, which is usually used for roofing materials, operates with pinpoint accuracy for both the gowns and the masks.  “Once that’s cut into shape, we fold them and bring them over to the welding operation where the arms are welded.  The entire process takes about two minutes for one gown,” Tracey explained.

Duro-Last engineers, product development and manufacturing staff collaborated to fabricate and manufacture the PPE products.  “We developed the product in conjunction with Beaumont Hospital in Metro Detroit.  They’re kind of the center of the epidemic here in Michigan, and we are starting primarily to send it to them,” Tracey revealed.  

Company engineers and production staff reformulated their current products and retooled their processes to make all of this a reality.  “Utilizing their expertise in manufacturing flexible PVC and fabrics, the team went from prototype to production to deliver delivery in one week,” Area Development reported.  There were 12 prototypes of the gown before they agreed on the 13th version, which is the one in production now.  

“This is about helping health care professionals in any way we can and at the same time keeping people employed...I am very proud of and impressed by the people in our company who quickly developed these products,” said Tom Saeli, Duro-Last CEO, in his interview with Area Development.

Each day, 50 workers are producing 3,000 gowns and 2,000 face masks.  More than 20,000 gowns have been produced thus far.  Fire departments, EMS, hospices and home care facilities have also benefited from Duro-Last’s supplies.  

Tracey couldn’t be prouder of the company’s willingness and ability to pivot their production as quickly as it has.  “The lady standing behind me at this table here goes home and makes masks on her own time when she’s gone...She typically doesn’t work in this building and just asked ‘Can I please come over here and work on this?’”  Producing the PPE products has actually increased Duro-Last’s workforce from 50 to 70 workers.  They partnered with Euclid Industries in Bay City to bring some of their staff to Saginaw, Tracey explained.

While Duro-Last’s roofing technology and products are typically used to protect buildings, they are now protecting healthcare workers.  “It is a real sense of pride for our business, for our owners...To be a small local family-owned business, we’re just trying to do whatever part we can, and we’re hoping others will do the same,” Tracey revealed. 

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Learn more about Duro-Last products.