Hearing Protection: Three Innovations to Follow

Three hearing protection innovations that are helping overcome workers’ resistance for wearing PPE.

• By David Kopf
• Aug 01, 2024

Like many elements of worker safety, protecting workers’ hearing requires balancing monitoring their environment, ensuring they have the right PPE, and still fostering their productivity. Fortunately, there are new innovations being developed to accomplish that balancing act.

To be sure, there’s much at stake. According to the National Institute for Occupational Health and Safety’s statistics on noise and hearing loss, roughly 12 percent of all workers have hearing difficulty; approximately 8 percent of all workers have tinnitus; about 25 percent of workers have been exposed to hazardous noise; and 53 percent of workers exposed to noise say they haven’t worn hearing protection.

That last stat is jarring. While OSHA might require employers to implement a hearing conservation program that includes PPE when noise exposure reaches 85 decibels or higher averaged over eight working hours, workers will eschew that gear. They do it for a number of common reasons:

• They find earplugs and earmuffs uncomfortable and ill-fitting.
• They feel the PPE makes it difficult to communicate.
• They underestimate the long-term risks posed by noisy environments, or are unaware of the risks in the first place.

Just to underscore those points, workers don’t wear hearing protection gear because of bad fit or discomfort; they have a tough time communicating while wearing the PPE; or they are unaware of environmental noise and its risks.

Fortunately, there are three hearing protection product innovations that address those reasons head-on.

Improved Fit and Comfort

Recent innovations in the design of earplugs and earmuffs have significantly focused on improving fit and comfort, which are crucial factors that encourage consistent use among workers in noisy environments. Providing more personalized and adaptable solutions not only aids in preventing hearing loss but also enhances overall safety and productivity in the workplace.

Custom-moldable earplugs. Companies such as Decibullz and Big Ear offer custom-molded earplugs that users can fit to their exact ear shape at home. This innovation utilizes thermoplastics that you can heat and mold. If the initial fit isn’t perfect, they can be remolded to achieve the desired fit. This technology not only ensures a perfect seal but also increases comfort, potentially boosting user compliance in wearing them consistently.

Advanced materials and design for earmuffs. Innovations in earmuffs have also seen significant improvements. For instance, new models from companies such as 3M Peltor and Decibel Defense provide better noise cancellation while being designed to be less bulky and more comfortable for long periods of wear. The use of padded, adjustable headbands and ear cups made with soft, hypoallergenic materials enhances comfort, making it easier for workers to wear them throughout their shifts without discomfort.

Better Communication

Noisy workplace settings such as construction or manufacturing are starting to benefit from devices that not only protect hearing but also enhance it. PPE can now provide hearing protection as well as the ability to filter and enhance certain sounds can be incredibly useful in noisy environments. These devices help in maintaining communication and situational awareness while also protecting the user’s hearing from harmful noise levels.

Advanced earmuffs with communication capabilities. New models of industrial earmuffs from companies like 3M Peltor, Sordin and SENA now include built-in communication systems that allow workers to communicate clearly even in extremely noisy environments. These systems often include Bluetooth connectivity and noise-canceling microphones.

Smart earplugs. These are earplugs that adapt to the noise level in the environment and reduce it to a safe level while still allowing for ambient sounds to be heard. This is particularly useful for workers who need protection from sudden high-decibel noises but still need to hear alarms or machine sounds.

Increased Environmental Awareness

Wearable sound exposure monitoring devices are working to help protect workers from the dangers of excessive noise exposure by giving them immediate feedback on their environment. These devices play a crucial role in hearing conservation programs by providing real-time feedback on noise levels directly to the wearer. Typically, these devices alert workers immediately when the noise exceeds safe thresholds so that they can take protective measures, such as adjusting their position or ensuring their hearing protection is properly fitted. 

Companies such as 3M and Honeywell are helping develop solutions that integrate advanced sensors and connectivity features to enhance workplace safety and compliance with occupational noise standards. These devices are part of a move towards smarter, more connected personal protective equipment (PPE) that not only prevents injury but also gathers valuable data for improving safety protocols and training.

Better yet, those alerts and data on noise exposure help cultivate a heightened awareness among workers about the risks of noise. Over time, this can lead to behavioral changes that see employees proactively manage their exposure to noise rather than relying solely on post-exposure reporting, which is certainly a sound solution.

This article originally appeared in the July/August 2024 issue of Occupational Health & Safety.