The ongoing COVID-19 disease significantly affects not only human health, it also affects the wealth of country’ economy and everyday routine of human life. To control the spread of the virus, face mask is used as primary personal protective equipment (PPE). Thus, the production and usage of face masks significantly increase as the COVID-19 pandemic still escalating. Further, most of these masks contain plastics or other derivatives of plastics. Therefore, this extensive usage of face masks generates million tons of plastic wastes to the environments in a short span of time. This study aims to investigate the environmental impact induced by face mask wastes and sustainable solution to reduce this waste. An online survey was carried out to identify the types of face mask and number of masks used per week by an individual from 1033 people. Based on this survey and available literature, this study quantifies the amount of plastics waste generated by face masks. However, this survey was limited with certain ages, country and durations (July–August 2020). Thus, the prediction of plastic waste generation, only provide fundamental knowledge about the mask wastes. Results revealed that there is a huge plastic waste remained in land and marine environment in the form of mask waste, which will contribute to micro-plastic pollution. Therefore, this paper also highlights the sustainable approach to the mask production by integrating the use of natural plant fiber in the woven face mask technology to reduce the plastic waste induced by masks. Further, upcycling the mask waste and producing construction materials also discussed.