Anti-pollution filters are the key component in a cycling or motorcycle respiratory mask. The mask generally serves as a support and doesn't filter anything. The filter, depending on its filtration standard, blocks fine airborne particles based on their size. When I created my Frogmask brand, I only found one manufacturer willing to produce small series with my constraints. It was located in China. None of the contacted French or European companies had agreed to manufacture for me. Life's twists and turns led to things changing. I'll explain why Frogmask anti-pollution filters are now manufactured in Italy.
The Frogmask brand almost disappeared
My Frogmask brand almost disappeared before its 3rd anniversary, even though sales were consistently growing by double digits month after month.
Last August, when I was about to reorder FFP2 filters from my Chinese manufacturer, he informed me that he had gone bankrupt and could no longer supply me. I should note that he was the only one who, in 2020, in the middle of Covid, agreed to custom-make them for me in very small quantities, given the standards of this industry. All French manufacturers had refused at the time.
Total panic, because I had about 2 months of stock left and 2 months to find a new manufacturer, get production started, and have them delivered with my small-series constraints – it was extremely tight. I was in complete panic because the products were popular, sales were growing, and it couldn't just stop like that!
My search for anti-pollution bike filters on Google
I wrote to all French, European, and surrounding (UK, Turkey, etc.) manufacturers visible on Google, and once again, very few responded. The French, still as inflexible as ever, immediately declined. Only one Italian agreed to work on a project worth a few thousand euros, which was nothing to him. It's worth noting that the 3D mesh that makes up the mask also comes from Italy. It must be said that they are very strong in the production of technical and high-end textiles. Again, he was the only supplier who had agreed to support me in my project when I did my research.
After 3 weeks and numerous exchanges, he validated the project, and I placed the order. He saved my brand without even knowing it! The stakes were so high that I asked to attend production in mid-November 2023. I had never seen how an FFP2 filter is made, so it was also an opportunity for me to improve my skills.
Here is the link to the video of the production of anti-pollution filters for those interested. The fully automated machine still costs almost a million euros! It can produce 4000 filters per hour!
Even more efficient anti-pollution filters
The best part of this story is that, while discussing my projects with Massimiliano, the boss, and his two employees, all super adorable, they found me THE solution to create a 2nd range of "sport" Frogmask masks with truly effective exhalation valves. Most valved masks on the market are ineffective because the valves are very basic and poorly positioned relative to the airflow exhaled from the mouth.
Producing in Italy ultimately costs me less than in China because transportation costs are divided by 5. The carbon footprint is also much better. Not to mention the responsiveness for future productions. The quality of the filters is also significantly superior, with 38% improved breathability compared to the Chinese filter.
PURE … JOY … !!! VIVA ITALIA !!!
Another great example of how bad news, with a critical impact, can lead to a great opportunity.
Why do we always wait for a disaster to question the status quo? This incident made me realize that supplier management is crucial and that you should never put all your eggs in one basket to spread the risks. So I will look for a second source of supply, just in case?
Each Frogmask mask comes with an FFP2 filter. They are sold individually, in a pack of 10, or in a promotional pack of 20 on the brand's website.
