Worn properly an earplug like the Howard Leight Max NRR 32 can be used in noise up to 110 dB(A). 110 dB is roughly equivalent to someone blowing a whistle a couple feet from your ear. Aside from being extremely irritating, it’s very dangerous for your ear. 120dB is typically recognized as the pain threshold and the point where damage to your ear can happen very quickly.
Under OSHA's Occupational Noise Exposure standard (29 CFR 1910.95), employers must implement a Hearing Conservation Program whenever an employee's 8-hour time-weighted average noise exposure reaches 85 dBA — the action level. At 90 dBA (the OSHA Permissible Exposure Limit), hearing protection is required. NIOSH's Recommended Exposure Limit is stricter at 85 dBA for an 8-hour TWA.
On their website, the Howard Leight company writes that the best earplug is the one that is worn properly, and we might add comfortably. We’ve found over the years that safety equipment that is comfortable and easy to wear is more likely to be used than alternates that are cumbersome or irritating.
To help you wear your ear plugs both comfortably and properly, we've taken a couple pictures to demonstrate the proper technique.
To properly fit an earplug, here are a couple of easy to use tips that will make it easier and more effective.
Roll the ear plug with clean hands into as narrow a tube as you can.
Reach over your head with your free hand and pull you ear gently up and slightly out to help open up the ear canal.
Insert the rolled up earplug with a slight turning motion until it is well inside your ear canal. The entire length of the plug should fit inside the ear with only a small amount protruding. (See photos). Hold the ear plug gently in place for 30-40 seconds as the foam expands so it doesn’t work its way out.
If the ear plug doesn’t seem to fit properly, remove it and try again. If you are new to wearing ear plugs, there is a natural tendency to only put a small amount of the plug into the canal. These soft earplugs will not damage the ear, and are made to be fit deeper and to expand fully to best protect your hearing.
Once you have inserted the ear plug, you will hear and feel it expand to fill the canal. If you are not used to this, it can be an odd, but not a painful, sensation. As long as the ear plugs remain clean and free from rips and tears they may be re-used, but at our great prices, you may as well treat yourself to a new pair each time you need ear protection.
A note on NRR (Noise Reduction Rating). The NRR printed on the package is an EPA-required lab-measured rating (40 CFR 211 Subpart B). Real-world attenuation is typically lower because insertion in the field rarely matches lab conditions. NIOSH recommends de-rating the labeled NRR by 50% for foam earplugs, 30% for pre-molded earplugs, and 25% for earmuffs when calculating protection against actual workplace noise. A Howard Leight Max at NRR 32 delivers roughly 12-13 dBA of real-world protection when de-rated (NRR 32 - 7 = 25; 25 ÷ 2 = 12.5 dBA reduction on A-weighted noise, per the NIOSH single-number method).
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Photo credit: ©Ioana Adam's Images via Canva.com
Frequently Asked Questions
Why do my earplugs keep falling out?
The most common cause is incomplete insertion. If a foam earplug is only partially inserted (a large portion of the plug still visible outside the ear), the foam won't fully expand inside the canal and will work its way out as you talk or move. Follow the roll-pull-insert-hold technique from the steps above: roll the plug into a narrow tube, pull your ear up and slightly out to straighten the canal, insert with a slight turning motion until only a small amount of the plug protrudes, and hold in place for 30-40 seconds while the foam expands. If the plug still won't seat correctly, try a smaller size or a different shape (some foam earplugs come in a tapered shape that seats more easily in narrower canals).
How deep should earplugs go in your ear?
A properly-fitted foam earplug should be inserted deep enough that only a small amount protrudes from the ear — typically about a third of the plug visible from the outside, with two-thirds seated inside the ear canal. Soft foam earplugs are designed to fit deeper than most first-time users expect; they will not damage the ear canal at recommended depths. If you can see most of the plug from the outside, it's not deep enough and won't achieve the labeled Noise Reduction Rating. For pre-molded and custom earplugs, follow the manufacturer's specific insertion depth guidance — these plugs are designed for a specific seating depth and inserting them further can be uncomfortable without adding protection.
What NRR do I need for my job or activity?
The Noise Reduction Rating (NRR) needed depends on the actual noise exposure level. For an OSHA-compliant Hearing Conservation Program (29 CFR 1910.95), the goal is to reduce the wearer's time-weighted average exposure below 85 dBA. NIOSH recommends de-rating the labeled NRR by 50% for foam earplugs, 30% for pre-molded, and 25% for earmuffs. Practical guidance by activity: light construction (85-95 dBA) — foam earplug with NRR 25-32 (13-16 dBA real-world protection); heavy construction / power tools (95-105 dBA) — foam or pre-molded plug with NRR 30+ (15+ dBA real-world); chainsaw / firearms (110+ dBA) — double hearing protection (foam earplug PLUS earmuff, NRR combines with a +5 dBA bonus, not simple addition). See hearing protection and earmuffs for the range at each protection level.
What's the difference between foam and reusable earplugs?
Foam earplugs (like the Howard Leight Max or Moldex Pura-Fit) are disposable, single-use in most occupational settings, and use polyurethane or memory foam that expands to fill the ear canal. They're inexpensive, offer the highest NRR ratings (up to 33), and require the roll-pull-insert technique to seat correctly. Reusable earplugs (pre-molded, banded, or corded) use flanged silicone or thermoplastic that seats mechanically without expansion — they insert faster (no roll-and-hold), can be washed and reused for weeks, but generally have lower NRR (22-28) and may fit fewer ear canal shapes. Custom-molded earplugs — shaped to the individual wearer's ear canal from an impression — offer the highest fit consistency and comfort but cost significantly more. Match the plug type to how often you'll wear it and how consistent the fit needs to be.
Can I reuse foam earplugs?
Foam earplugs can be reused as long as they remain clean, dry, undamaged, and haven't lost their expansion recovery. Inspect each plug before use: if the foam has visible dirt, cerumen (earwax) buildup, tears, or the plug fails to fully re-expand after being rolled, discard it. In dirty or wet environments (construction, food service, healthcare), foam earplugs should be treated as single-use per shift. NIOSH advises against reusing foam earplugs across multiple wearers due to hygiene risk. If cost is a concern for high-use environments, look at reusable pre-molded earplugs (which are designed for repeated cleaning) or custom-molded plugs.
When are earplugs not enough on their own?
When the actual noise exposure exceeds what the earplug's real-world attenuation can bring below 85 dBA (OSHA's action level), you need double hearing protection — an earplug PLUS an earmuff. Common scenarios that require dual protection: chainsaws (110-120 dBA), pneumatic hammers (100-115 dBA), jet engine ground operations (140+ dBA), firearms without a suppressor (140-160+ dBA impulse noise). When combining an earplug and earmuff, the combined NRR is calculated as the higher of the two ratings plus a +5 dBA bonus, not simple addition (per NIOSH's dual-protection formula). For sustained exposure above 115 dBA or any exposure to impulse noise above 140 dBA, dual protection is required regardless of the individual NRR ratings. See earmuffs for the pairing options.
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