An Adelaide-based packaging company has demonstrated the remarkable agility of Australian manufacturing, transforming its operations during the pandemic to establish one of the southern hemisphere's largest medical mask production facilities.
The Emergency Pivot
In April 2020, amid dire personal protective equipment shortages, the family-owned Detmold Group received an urgent call from the state government requesting help to protect the community. The company, traditionally known for producing coffee cups and McDonald's packaging, faced a monumental decision.
Chief executive Zoe Detmold revealed the company initially hesitated, acknowledging that medical mask production wasn't their core competency. Despite this, the Adelaide firm rose to the challenge, embarking on what would become an extraordinary manufacturing transformation.
Lightning-Fast Transformation
What would typically represent an 18-month project was compressed into just 18 weeks of intense activity. The company retooled its entire operation, shipping specialized equipment from overseas and establishing completely new production lines.
Engineers collaborated closely with health experts to ensure medical-grade standards, while staff from diverse backgrounds—including chefs, pilots, and health workers—joined the factory floor to boost production capacity. This collective effort resulted in the birth of Detmold Medical.
At the pandemic's peak, the operation was running 24/7, producing an astonishing 145 million masks from what had previously been an unused factory space.
Overcoming Challenges Through Innovation
One significant hurdle emerged: Australia's lack of local PPE testing facilities was causing critical delays. Detmold Medical responded by establishing an onsite laboratory through collaboration with Flinders University, UniSA, VicLabs and the CSIRO.
This innovative solution proved transformative for quality assurance. Ms Detmold described it as a real game-changer in ensuring our products are of the highest standards and fit for purpose.
The company has emphasized the importance of the Australian Made logo on their products, noting it represents credibility, reliability, availability to customers and has been crucial in building trust.
Enduring Legacy and Expansion
Now celebrating its fifth anniversary, Detmold Medical has evolved beyond pandemic response to become one of the southern hemisphere's largest manufacturers of respirators and face masks.
While healthcare demand has stabilized, the company has successfully expanded into new sectors including mining and construction, while also exploring sustainable manufacturing practices for PPE production.
Ms Detmold reflected that this journey highlights the enduring strength, innovation, sophistication and resilience of local manufacturing, proving how Australian businesses can rapidly adapt to meet national needs.
