Although the pandemic has passed, heightened hygiene awareness has kept many people wearing masks. These masks are made from non-woven fabric, which is essentially plastic and non-degradable. Over the three years of the pandemic, the massive global disposal of masks has caused significant environmental damage. Hong Kong-based startup OKOsix has developed an alternative material that can replace non-woven fabric, fully degrading within six months—a groundbreaking advancement for the industry. Last year, OKOsix completed the Hong Kong Science Park Global Booster Programme, spending six months in Silicon Valley, where they successfully expanded their network and gained a clearer vision for future development.
Aside from masks, many other medical and personal care products, such as PPE worn by doctors and nurses, facial masks, diapers, and sanitary napkins, are made with non-woven fabric. The raw fibers used to make these materials typically contain polypropylene (PP) or polyethylene (PE), both of which are plastics.
“To prevent the spread of germs, medical waste is mainly incinerated, which releases harmful substances into the air. Other personal care items are often sent to landfills, where they remain undegraded or end up polluting the ocean, forming massive garbage islands across the world,” says Eddie Yu, co-founder and CEO of OKOsix.
A Conversation That Sparked Innovation
Eddie graduated from the Chinese University of Hong Kong with a degree in physics and later joined an international materials company, where he worked in research and sales. Over time, he realized that his true passion was in developing new materials.
At the start of the pandemic, Hong Kong faced a severe mask shortage, prompting Eddie to set up a production line to help meet demand. However, as more companies joined the mask industry, production surged—with over 200 factories in Hong Kong manufacturing masks at its peak. Anticipating a sharp decline in demand post-pandemic, Eddie decided to sell his mask production business.
One day, while teaching his five-year-old niece about waste sorting, she asked him where she should dispose of a mask. Eddie explained that masks couldn't be recycled, to which she replied, "Then masks are really bad for the environment."
“That one sentence felt like a slap in the face, it was the moment my entrepreneurial inspiration struck. I wanted to develop a new material to replace non-woven fabric,” Eddie recalls.
With extensive knowledge of materials and applied sciences, Eddie partnered with a friend who had deep expertise in manufacturing and production. Their skills complemented each other perfectly, leading to the founding of OKOsix.
Through extensive research, Eddie and his team discovered that while many scientists had attempted to develop alternatives to non-woven fabric, no solution had yet been successfully commercialized.
OKOsix's team developed OKOmer, a patented material made from natural plant fibers and waterproof compounds. Through chemical processes, raw ingredients are transformed into granules, which then undergo various production steps to become fabric-like materials used as semi-finished products.
OKOmer possesses water absorption and waterproof properties and can be adjusted for softness or rigidity to suit different applications. The most advanced version of OKOmer currently serves as an alternative to non-woven fabric for masks and facial masks. Another formulation is being fine-tuned for use in diaper filtration layers, with research and development nearing completion.
OKOmer has undergone testing and certification, proving that it can fully degrade within six months, leaving only water and carbon dioxide.
OKOsix conducted a biodegradability experiment by mixing half-degraded material with soil and using it to grow plants, then comparing the results with plants grown entirely in soil. The findings showed no significant difference in growth rate or health, confirming the material's environmental safety.
Lowering Costs Through Mass Production
Given Eddie's previous experience running a mask factory, OKOsix established its own production facility to manufacture OKOmer-based masks.
“Masks made with OKOmer function just as well, if not better, than traditional masks. People who wear masks for long periods often experience skin allergies, but OKOmer has antibacterial properties that help prevent sensitivity. Additionally, traditional masks tend to develop odors due to bacterial growth from saliva, while OKOmer’s antibacterial features eliminate this issue.”
OKOmer can also be molded into flexible shapes to replace metal nose wires in masks. OKOsix's factory in Kwai Hing spans 4,000 square feet, with a maximum monthly production capacity of 2 million masks.
Currently, the facility manufactures masks in four sizes, which customers can order online or in bulk for corporate use.
“Business-to-consumer (B2C) isn't our primary focus, as building a brand requires significant resources. We prioritize business-to-business (B2B) collaborations—developing alternative materials to replace PP and PE, similar to GORE-TEX, which allows brands to design a variety of products using our materials.”
One of the biggest hurdles for sustainable materials is cost. Initially, OKOmer was ten times more expensive than standard PP or PE. Through continuous research, formula improvements, and resource optimization, the cost has now been reduced to twice that of traditional plastics.
“We are in the process of securing financing to purchase production equipment and further refine our formula. Once we scale up manufacturing, we believe the cost will only be about 5% higher than conventional materials, which we anticipate achieving within two to three years.”
According to research from a U.S. market analysis firm, OKOsix is the world's first company to create fully biodegradable non-woven fabric as an alternative to PP and PE. Companies in the Netherlands and Canada are currently testing OKOmer, with results expected within four to six months. Upon successful completion, they plan to develop and launch new products using this material.
Expanding Biodegradable Solutions
Eddie first introduced his concept at a 2021 entrepreneurship competition at the Chinese University of Hong Kong. Although he was eliminated in the second round, a judge found the idea intriguing and recommended that he pitch it to the Hong Kong Science Park.
OKOsix later joined the Science Park's IDEATION and Incubation programs, completing both ahead of schedule. They are now participating in the Acceleration Program, which provides HK$1.2 million in funding for incubation and HK$4.8 million for acceleration.
In 2024, OKOsix was selected for the Science Park's Global Booster Programme, where five Hong Kong startups underwent rigorous six-month training in Silicon Valley to explore the U.S. market.
Through this experience, OKOsix recruited key talent, including a Stanford University chemistry PhD as its Chief Innovation Officer and a University of California, Berkeley chemistry professor as an advisor.
The program also introduced OKOsix to American investors, and they are now pursuing a seed funding round to raise $3 million while seeking investors with synergistic interests.
Eddie sees Hong Kong as an emerging hub for innovation, stating, “If the U.S. is the paradise of tech startups, Hong Kong is still on the ground, but it’s a rising star with limitless potential.” OKOsix plans to establish a presence both in the U.S. and mainland China, where subsidies from Qianhai’s Dream Factory provide incentives.
Beyond non-woven fabric, OKOsix aims to develop bio-based replacements for single-use plastics, including testing alternative materials for rapid test kits used during the pandemic and everyday items such as pregnancy tests and vitamin test kits.
Additionally, OKOsix is researching biodegradable substitutes for plastic-based daily essentials, such as calculator casings and kitchenware handles—that don't necessarily require degradation but offer a more sustainable alternative.
With countries pushing for carbon neutrality by 2030, OKOsix sees vast opportunities in advancing environmentally friendly materials.
The Role of Artificial Intelligence
Artificial intelligence (AI) has recently surged in popularity, permeating every aspect of human life and playing a crucial role in technological innovation. OKOsix has integrated AI into its material development process, leveraging material data to train AI models. These models perform complex calculations to assist in the creation of groundbreaking materials, which are then fine-tuned manually for optimal performance.
Additionally, OKOsix faces the challenge of connecting with senior executives at large corporations to introduce and promote OKOmer, its biodegradable material. Since these key figures are often difficult to reach, OKOsix utilizes AI models to identify and engage with them through various channels, ensuring they understand the benefits and applications of OKOmer.
Translation from original source: edigest.hk