Sound plan

DO YOU have a noise problem at work? If your attempts at conversation require shouting within a two-metre radius, then the answer is probably yes.

Enter the realm of workplace noise - an occupational peril that demands attention. The Health and Safety Executive (HSE) estimates that over two million workers in the UK endure unacceptable noise levels on the job. Tinnitus UK's survey from December 2022 reveals that one in ten manufacturing workers exposed to noise suffer from tinnitus. Shockingly, 39% of respondents admit to facing workplace noise without any hearing protection.

The onus rests on employers to protect their staff from harm. While current regulations mandate risk assessment, and provision of information and training at noise levels of 80 decibels (dB), hearing damage kicks in at around 85dB.* To put this into context, a standard household vacuum cleaner emits around 80dB. Exposure to noise levels of 100 dB for longer than 15-minutes is not recommended and regular exposure of longer than 1-minute risks permanent hearing loss.

* Extended exposure to 80dB can cause a measure of hearing loss over time, according to the TUC’s ‘Noise at Work’¹ article.

Preventing noise-induced hearing loss

Industrial settings are notoriously noisy. From ear-piercing manufacturing plants to bustling construction sites and factories, such workplaces can pose a real threat to workers' auditory well-being. Without proper hearing protection, workers are vulnerable to developing permanent and irreversible noise-induced hearing loss (NIHL). 

The most common guardians of auditory health are ear defenders and earplugs, both of which reduce the intensity of sound reaching the ears, thereby decreasing the risk of NIHL. Far from being a luxury, this kind of industrial hearing protection is an essential component of a safe work environment, and mandated by law.

By being proactive, employers can prevent noise-induced hearing loss, enhance workplace safety, boost employee well-being, morale and productivity, and ensure legal compliance set out in the Control of Noise at Work Regulations 2005.²

Standard vs. custom solutions

So, as HSQE professionals, how do you evaluate the best solution for your workforce? Below is a quick run through of the options:

Standard earplugs and ear defenders 

Pros: 

• Such devices restrict noise levels across all frequencies 

Cons: 

• Absolute removal of all noise levels across the frequency range can amount to overprotection, creating issues of its own. Workers feel isolated because they can’t talk to each other and productivity suffers when they can’t operate machinery effectively or respond to instructions. Worse, poor situational awareness and not being able to hear safety warnings can cause potentially fatal accidents. In addition, workers may be tempted to partially or fully remove hearing protection for short periods, but even temporary exposure to excessive noise risks permanent hearing damage.
• The universal fit of standard plugs and defenders also falls short. The human ear is as individual as the fingerprint, but foam plugs come in standard sizes only and ear defenders have limited adjustment mechanisms, meaning that some harmful sounds inevitably seep through. Foam plugs can offer reduced levels of the claimed protection level due to incorrect insertion.

Customised hearing protection

Pros: 

• Made-to-measure custom filtered plugs form a superior seal around the ear canal. Unlike their standard counterparts, bespoke plugs boast state-of-the-art filters that are specially designed to reduce specific sound frequencies. This allows essential sounds to pass through while blocking out damaging noise, enabling staff to hear instructions or hold conversations without having to remove their plugs. 
• Bespoke plugs contain filters that come with different decibel ratings and reduce noise levels by the stated amount. This is known as acoustic attenuation and expressed as SNR (Single Number Rating). For example, 20dB rated plugs would drop the noise level in a 95dB working environment to a compliant level. 
• Custom filtered plugs are individually fitted, making them comfortable enough to be worn for long periods of time. This is ideal in workplaces that are prone to unpredictable noise spikes and makes for a safer and more productive environment all-round.

If you’re unsure how noisy your workplace is, you can get a full sound survey by downloading a free noise tracker app on your smartphone. Individuals can contact the RNID for a free hearing check³ over the phone.

Fast fitting

Custom filtered plugs are bespoke to the wearer, so a qualified technician visits your site to take individual ear impressions. This involves inserting a foam stop into the ear canal before injecting medical grade silicone to form an impression, all of which takes around 10 minutes per employee. These impressions are sent to a special laboratory and scanned into a computer that generates a 3D-printed version ready for use. The whole process can be turned around in just eight days.

Environmental and cost advantages

Custom filtered plugs last around four years, while foam earplugs need to be replaced up to four times every day, making them more expensive over time. And even though ear defenders are reusable, they still need replacing on average twice a year.

Cost comparison* over four years for a team of five people:

Foam ear plugs: £2,500

Ear defenders: £1,100

Custom filtered plugs: £550 

* These numbers assume an average usage of foam plugs up to four-time every day and twice-yearly replacement for ear defenders.

Now consider the environment. Foam earplugs aren’t currently recyclable or biodegradable and typically end up in landfill having the same devasting impact as plastic straws. On average, one worker could generate almost eight litres of waste over a four-year period. In addition, most are mass-produced overseas, contributing to CO₂ emissions. 

Custom earplugs are 3D-printed in the UK, minimising shipping. So besides being cheaper in the long run, custom earplugs are greener too, helping businesses eliminate single use plastic and reduce their carbon footprint.

Boosting morale and productivity

The link between constant noise exposure and fatigue, stress and irritability, is well established, all of which reduce job satisfaction and motivation. 

Employers that provide adequate industrial hearing protection demonstrate their commitment to employee well-being and show that they value their workers’ health, fostering a positive work culture, enhanced morale and job satisfaction. When employees feel safe and supported, their productivity increases, leading to improved overall performance and organizational success.

The real costs

Failure to provide adequate hearing protection can result in prosecution and heavy fines. In 2021, a court ruled Indigo Sun Retail pay £241,277 in light of noise management negligence, while in 2018, The Royal Opera House incurred fines estimated at £750,000 for a hearing-related case. Factor in reputational damage and the potential financial toll becomes staggering. 

Conclusion

Given the prevalence of noise-induced hearing loss and the need for compliance, providing high quality hearing protection is essential. While off-the-shelf solutions are readily available, custom hearing protection offers superior comfort, protection, and value for money, an investment that safeguards employees’ well-being and creates a safer working environment.

Ultimately, when it comes to industrial noise, prevention is key. By working together, we can create a quieter, safer, and healthier future for industrial workers around the globe.

References

1 https://www.tuc.org.uk/sites/default/files/extras/noiseatwork.pdf

2 https://www.legislation.gov.uk/uksi/2005/1643/contents/made

3 http://tinyurl.com/4vfu4u2u

Kevin Davies is the technical innovations director at Minerva Hearing Protection. For more information, visit https://minervahearing.co.uk/