Making masks in Sandusky

SANDUSKY — They're known for making mementos, which can help remind people of defining moments in life. Though, a few months ago, the co-owners of Sandusky-headquartered Harbourview Products International pivoted to produce an item that can help save lives. Earlier this year, Harbourview acquired $500,000 in state funds through a competitive process, known as the Ohio Personal Protective Equipment (PPE) Retooling and Reshoring Grant. In short, the grant enticed companies to transition their normal manufacturing operations into small, individual hubs, where they could purchase the necessary equipment to combat COVID-19 in Ohio. As of this week, a record 5,234 hospitalizations occurred on Tuesday with 6,753 statewide deaths attributed to the coronavirus. Scientists don't see the spread slowing anytime soon with the majority of counties, including Erie, deemed "areas of very high exposure." The grant process only awarded about 60 statewide companies with funds, which included Harbourview. Sandusky residents Tim Boals and Kevin Weibel, who co-own Harbourview, believe their company is the only one to secure grant funds within a 50-mile radius. Both said they were "grateful to the state" for this opportunity. "We saw the need here for PPE. For the longest time, you couldn't get hand sanitizer, gloves or masks. In some places, you still can't," Boals said. "So we looked into all the different types of ways and tried to figure out the easiest way to produce it. We wanted to get up and running as fast as we could." A new direction Both Boals and Weibel understand the tremendous hindrances created by COVID-19. For starters, it has personally, and negatively, impacted their livelihoods. Their business — which largely caters to creating souvenirs for professional sports teams, amusement parks, cruise lines, restaurants and casinos — encountered numerous setbacks these past few months. "Early on in 2020, we realized that this COVID situation is real, and it's going to be affecting us," Weibel said. "Hospitality has been one of the hardest-hit industries because of COVID: It affects travel, hotels, amusement parks and more. All of those people who are our buyers suddenly were not placing orders because they didn't have people coming since they were shut down." After previously working at Cedar Point, each knows firsthand the importance tourism can have on communities, especially ones dependent on it like Sandusky. "Without having a destination to go to, people are not going to be spending money," Boals said. Beyond their business, they're also concerned for the well-being of their family, friends and fellow neighbors. "We are talking about the betterment and the health of our community," Weibel said. "We love our souvenir business, but this is something our community needs. There is nobody making KN95 masks." But, now, Harbourview does. What is a KN95 mask? From a distance, an N95 mask — what many people have likely heard of before — and a KN95 mask — what many people have likely not heard of before — look similar. The main difference: Federal officials classify N95s as medical-grade masks. KN95s aren't. But that doesn't make them any less safe or efficient, Weibel said about KN95s. If it did, then Harbourview wouldn't have received state funds, vetted by the Ohio Department of Health, to produce KN95s. "It's really just a matter of how secure the fit is," said Boals, when describing the differences and comparing the two. "The medical ones connect around the back of the head and are a much tighter fit." Added: Weibel: "The KN95s fit behind the wearer's ear via an elastic earloop, providing a more comfortable and casual fit. They're also much more effective than the cloth masks that many people are wearing or even the surgical masks. Normally the KN95s come from China, but we are making them right here in the USA." Each mask made by Harbourview features five layers of protective, non-woven cotton material. The masks offer structural support; filtration of viruses, bacteria and dust; durability; and wearability. "If you're around people, or you go to restaurants or a dentist's office or barbershops, anywhere you are going to be around people, it's 100% the best mask you can wear to protect yourselves and those around you," Weibel said. "And these masks are hard to find," Weibel added. "This is a way we can help our fellow Ohioans and our fellow community to stay safe for themselves and those around them." How though? Giving back Along with the $500,000 grant, Harbourview invested a sizable, yet unspecified, amount of private capital to transform the basement of its West Market Street headquarters, formerly a city firehouse, into a sterile production facility. For instance, Boals and Weibel needed to install a freight elevator, which drops down from a street-level surface into the basement. They require an efficient way to transport pallets, which can individually weigh upward of 3,000 pounds. Pallets carry massive cotton rolls used to make the masks. At any given time, several-dozen rolls fill up Harbourview's entire warehouse. Down in the basement, a miniature manufacturing operation popped up in once-empty storage space. Boals and Weibel take turns on various portions of the assembly line. It's broken up into three major components: • The mask-making machine, where, through computer programming, it can mold, cut and shape KN95s from the raw materials • The mask-packaging machine, which places them into single plastic sleeves • The mask-UV sanitation machine, which ensures the sterilization of the products before getting shipped out. Harbourview's grant came with many stipulations. For instance, it needed to build a filtration system in hopes of keeping toxins permanently away from this secure venue. Harbourview also saw an upgrade to the facility's electric equipment, powering these high-voltage machines. "This is why more people aren't doing this: It's very hard and requires a lot of effort," Boals said. "And not just that, it's very expensive. But we were able to find the equipment because we already deal in markets like these, and we had the space to make our machines." From purchasing the equipment to setting up these machines before finally flipping the "on" switch, Weibel estimates this entire process took about four months. In fact, he and Boals just began producing masks a few days before Thanksgiving. When at maximum capacity, Harbourview can churn out about 36 masks a minute. "And we have enough material to make half-a-million pieces," Weibel said. But, to Boals and Weibel, it's not about reaching certain quotas or reclaiming lost income opportunities from their sidelined souvenir business. Simply put, it's about keeping locals safe. "We are not looking to make a lot of money off of this," Boals said. "Instead, we are looking to help the community and bridge our gap until we can start doing our core business again. We know this is not a long-term solution for our business. We are just hoping it can sustain us." Harbourview, going above and beyond the grant's requirements, decided it would donate a large supply of its stock to schools, nonprofits, hospitals, nursing homes and other organizations in need. For everyone else, people can buy these KN95s. Anyone can stop by Harbourview between 9 a.m. and 5 p.m Mondays through Fridays to purchase a pack of 100 masks. "There is a lot of talk of the vaccine coming soon, but there has also been a lot of information that masks aren't going to go away anytime soon," Weibel said. "Even when the vaccine hits, there will still be a need for masks, well into next year, and we both feel this is something our community needs to stay safe." Want a mask? • What: Harbourview Products International, a Sandusky-headquartered company, received a state grant to produce KN95 masks. The company's co-owners decided to donate a large chunk of these masks and sell them at a discounted price to community members They're valued at $1.29 per mask but only come in packs of 100. • Where: People can stop by Harbourview's office, 901 W. Market St., Sandusky. It's a former city firehouse. • When: People can step into the lobby from 9 a.m. to 5 p.m. Mondays through Fridays. • More: People can visit harbourviewproducts.com to also purchase the mask.