Face shields

Gatineau manufacturer transforms factory to supply frontline workers

Responding to Prime Minister Justin Trudeau’s call on Canadian companies to manufacture medical equipment to help stop the COVID-19 pandemic, one Gatineau company stepped up big time. Over the last week, Advanced Coatings Engineering (ACE), responded by essentially turning its window securing business into a facial protection factory.

Typically, the company designs and manufactures thin, clear laminates composed of high-grade polyethylene that make windows burglary, gunshot and explosion resistant. But with COVID-19 continuing to spread, ACE re-tooled its operations to manufacture face shields to protect healthcare workers and law-enforcement officers.

In an interview with the Aylmer Bulletin, ACE’s Chief Operations Officer, Gabriel Draven, explained that the transition came out of resiliency and a will to contribute to the national battle against the crisis. In March, when the coronavirus initially started spreading in Canada, ACE received a request from a government of Canada driver who was concerned about his safety, Draven said. Noting that the company provides a very unique service, Draven explained that ACE is improvisational in its designing of products and is used to acting on the fly.

So, the company quickly manufactured a vehicle shield for limousine drivers, taxi drivers and chauffeurs, which sold rapidly across North America. Studying the rate of COVID-19 infections among healthcare workers in Italy, where the virus exploded early, Draven noted that 20 per cent of infections were caused by facial transmission. “Not just the mouth, but the eyes, even the ears,” he said.

Knowing Canada would inevitably get hit by the virus soon after Italy, Draven believed Canadian healthcare workers would need a form of affordable, effective and easily wearable facial protective gear. Draven also noted that resource consumption in the medical field has been extreme during the pandemic, as healthcare workers across the country have been going through masks and gloves at an unprecedented pace.

“It solves multiple problems,” he added. The new face shields are made with a medically-certified polyethylene used to make their window laminates – which the company says are widely recognized as some of the best in the world. “It’s just got slightly different treatments,” he said. “It’s clear, it’s cleaner through the supply chain and it’s got an acrylic coating on it.”

Known as the ACE ClearView Face Shield, the product provides clear visibility, is hydrophobic - meaning that it will not fog - and is easily cleanable for repetitive use. Covering the entire face and then some, the face shields have a wrap-around barrier that protect wearers from pathogens.

ACE has also equipped the shields with special clips that easily attach to all kinds of standard or safety eyewear. “Our face shields slip onto those glasses in seconds,” Draven said.

Currently manufacturing 2,000 face shields per day, ACE has sold more than 10,000 so far. The company intends on producing between 50,000 and 60,000 face shields per day and has discussed with the federal government the possibility of outputting three million units. Most of the work will be done at ACE’s headquarters in Gatineau. 

The company has already received orders from the United States, North Africa and South America. Locally, only the Cornwall Hospital has purchased the face shields and has begun using them. ACE is working to supply their product via the Government of Canada’s procurement process to ensure that they can provide as much support to Canadians as possible. “I know from government officials that I’ve spoken to that they’re swamped,” Draven said. “They’re doing the best they can.”

The company conceived the idea, designed the product and unveiled its first prototype within a few days, Draven said, noting that ACE’s plant in Gatineau has dedicated almost its entire staff to manufacturing face shields and protective shields for vehicles, in response to the crisis.

To ensure a safe environment for its employees and products, ACE has invested in ultra-violet decontamination lights and has enhanced its safety and hygienic precautions. “We have health logs for everyone for every day,” Draven said. “We’re just taking the precautions that many other people are taking – face masks, hand protection and gloves.”

For Draven, being in a position to provide help for Canadians in a time of dire need is very gratifying.  Despite having been in business for almost 30 years providing products around the globe, Draven finds it strange that the local community doesn’t really know much about ACE.

Hoping for more local recognition going forward, ACE has proposed to the Government of Canada’s procurement office to retain the ability to manufacture face shields locally for international export or in case another pandemic arises.

“We’re talking about creating local manufacturing capability,” Draven said. “We’re talking about exporting for hard currency; we’re talking about hiring people locally; and, we’re retaining the capacity to make emergency products right in the community.” Draven mentioned that ACE has been in talks with Aylmer MP Greg Fergus and other government entities to help expedite the local supply process, noting that things have progressed smoothly so far.

No matter how hard the crisis is for Canadians, Draven sees no reason why the country can’t come out stronger on the other side. “I think this is a fabulous opportunity for Canada to reindustrialize itself,” he said. “We could be servicing our neighbours and we could be servicing the world.”

Based on rue Jean-Proulx, in Gatineau, ACE is a specialized plastics company, with 20 employees, that focuses on unique security applications.

Providing security enhancement products all over the world since 1991, ACE’s client base has featured a wide variety of military, government and media, including the Canadian Armed Forces, the United States Navy and the Washington Post.