Meet the hero of Miraj who made 4500 masks at home to fight COVID-19

Mail express guard Vishal Kalage talks about the process of making face masks and face shields at home and what inspired him to take up the task in the second episode of 'Real Heroes of Coronavirus'

Mid-day online journalists interact with the frontline workers in a new series 'Real heroes of coronavirus'. Media photographers, reporters, railway staff and medical workers tell their stories of grit, determination and every-day challenges in times of the pandemic.

Mail Express Guard Vishal Kalage has been working with Central Railway's Miraj division in Sangli, Maharashtra for 11 years. After the Railways decided to stall passengers train services, Kalage, who studied micro-biology, decided to use the lockdown period by making masks and face shields at home with the help of his wife and mother and contribute in the fight against the coronavirus pandemic.

Vishal Kalage distributes face masks to doctors, police staff and common people free of cost

We spoke to Vishal Kalage about his noble work and what it feels like to contribute to the society in the fight against coronavirus.

Here's an excerpt from the interview.

What inspired you to take up the task of making face masks?

When the lockdown was imposed, I went to buy medicines for my mother, who is an heart patient and I inquired about the cost of a disposable face mask. I was surprised when the shopkeeper told me that the face mask would cost Rs 30 and had to be thrown away after six hours of use. That is when I decided that I should make face masks.

When I pitched the idea to my wife (Rohini) and mother (Menakshi), they immediately agreed to the plan. My wife has done a course in fashion designing, she made few sample masks before we zeroed in on the final product.

Speaking about the shortage of face mask in the market due to the sudden demand, which emerged after the outbreak of the coronavirus cases in Maharashtra, Vishal said, "Honestly, there were no sanitisers at that time; hand wash was also not available and many medical shops were selling available stock at a higher price. At the same time, due to panic buying many front line workers including doctors and police staff did not have masks. Seeing the crisis that had emerged due to the shotage in supply of masks, I decided to make face masks at home and help the country fight the coronavirus pandemic."

What challenges did you face while making face masks at home?

Due to the nationwide lockdown, the fabric required to make masks were not available in the market. After searching four to five orthopedic medical shops, I finally got the required fabric from which I could make face masks at home. I purchased 10 (2x6) bedsheets at Rs 360 per bedsheet for making the masks. Five bed-sheets were used to make the lace while the other five bed sheets were used to stitch the main bracket of the face mask (three tier/plating of the face mask).

Vishal Kalage's wife sitches face mask at home (on left) and she posing with the final mask which was made at home (on right)

When did you start making the face masks?

On Day 2 of the initial 21-day nationwide lockdown, we started making face masks at home. In the beginning, we were able to stitch 160 face masks on a daily basis. Now we stitch 200 mask everyday. To date, we have stitched over 4,500 face masks. The face masks have been distributed free of cost to the railway staff, police staff and even hospitals among others.

How did you manage the production, did you hire people or the family managed it?

Initially, we hired two women from the garment industry, who had lost their livelihood due to the lockdown. The lace work was done by them, one would do the cutting while the other woman would work on the laces. The rest of the work required for making the masks was looked after by my wife, mother and myself.

Although the women worked for a few days, Vishal said he paid them adequate sum to sustain during the crisis.

Can you take us through the process of making face mask at home?

The cloth pieces are cut from the bed sheets as per the required size, dipped into dettol for nearly two hours and left out under the sun to dry. Once the pieces are completely dry, we start the process of stitching the mask. After the stitching, the face masks are ironed at 350 degree celsius for three minutes on both sides.

Explaining why ironing the face masks was important, Kalage said, "Being a microbiology student, I realised that the face masks will have to be bacteria free and clean, which is why we decided to press it under 350 degree celsius. This way we created a sterilisation process at home only."

To date, Vishal Kalage and his family have made 4500 masks and 150 face shield which has been distributed free of cost

After the masks are ready, Vishal's daughter Nakshaytra and son Nakshayraj help him in packaging by making a bundle of 50 face masks each. The kids then arrange these bundles in a bag which Vishal Kalage distributes to the doctors, police staff and the public at free of cost.

Besides face masks, Vishal also makes face shields at home. Using lamination sheets which his school going children use, Vishal with his wife's help made face shields at home. "We use lamination sheets and teflon sheets to make simple yet protective face shieds at home," he said.

How did the idea of making face shields come up?

While buying bedsheets for the face masks, I was shocked to learn that face shields made up of a plastic layer with a fibre like headband were sold for Rs 550 in medical shops.

I came back home with the pictures of the shield and referring the pictures I made my own face shield. The final product I made at home cost me Rs 80. Moreover, the shields are reusable, scratch proof and water proof and it can protect the doctors or the police staff directly from the saliva or the droplets of the COVID-19 patients.

Vishal Kalage has been working as a mail express guard at Miraj with Central Railway's Pune division since the last 11 years

How did you manage the expenses?

My wife and my mother helped me a lot and supported me. In the beginning, we used our little savings to make masks and face shields at home. But as the good word spread, our friends and family came together and contributed and soon I had Rs 14,500. This amount was used to make more face masks and face shields at home. The Railways also helped us by providing 10 linen blankets free of cost.

What precautions do you undertake to stay protected against COVID-19?

Whenever I come back home after distributing masks or have been out for personal work, I ensure to take bath. Before entering the house, I sanitise my bike and my shoes as I have small children and elderly mother, who is a heart patient. I take all these measure to make sure that no one should get contaminated and my family is safe and protected against COVID-19. I would request people to follow the hygiene instructions given by the government, stay home and be safe."

Vishal made the face shield at home at a nominal cost of Rs 80 

How do you feel now that you are able to contribute for a noble cause during such a crisis?

The feeling of helping people and the country during the coronavirus crisis cannot be expressed in words. All I know is that at night, I sleep with deep satisfaction and happiness.

Rs 80
The cost of face shield which Vishal Kalage made at home

4,500
The number of face masks the Kalage family stitched and distributed free of cost

150
The number of face shield he made at home

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