Industrial Hearing Protection · For EHS Officers
Protection your crewactually keeps in.
Foam gets tossed, worn wrong, or left on the bench — and the audiogram still comes back worse. Big Ear molds a custom earplug to each worker’s ear: comfortable enough to wear a full shift, tuned to protect exactly as much as the floor demands. Twenty years building for facilities that can’t afford one preventable hearing loss.
Not on the bench.
Trusted on the floor at
Custom hearing protection deployed across aerospace, tire & rubber, paper, packaging, food, airlines, energy, and government — and worn by more than 250,000 people since 2003.
The math every EHS lead lives with
Foam keeps failing your program.
You buy protection by the box, and you still fail the audiogram. Here’s why disposable and one-size hearing protection quietly costs you more than it saves.
Real-world attenuation collapses
The NRR on the box assumes a lab-perfect fit. On the floor, foam is derated hard — the protection a worker actually gets is a fraction of the number you specified.
Comfort decides compliance
An uncomfortable plug comes out by mid-shift. A plug on the bench protects no one, no matter how good its rating looks on paper.
The loss is permanent — and recordable
Noise-induced hearing loss never comes back, and every standard threshold shift becomes a number that follows your facility.
Disposables never stop costing
You re-buy them forever, dispense them forever, and throw them away forever — and the exposure is still there tomorrow.
The decibels on your floor
Every 5 decibels cuts your crew’s safe time in half.
OSHA sets the action level at 85 dBA and the permissible limit at 90. Above it, allowable exposure halves for every 5 dB — so the louder the task, the faster a worker is out of compliance. Here’s where a typical facility lands, and how fast the clock runs.
−25 dB
Abrasive blasting at 115 dBA gives a worker 15 minutes before overexposure. The One® at −25 dB brings it to 90 dBA — a full 8-hour shift, in compliance — while your crew still hears speech and alarms. That’s the line between a recordable and a program that works.
What no one else brings to your floor
The reasons facilities standardize on Big Ear.
The One® — patented flat attenuation
USC-developed. Workers hear speech, alarms, and each other clearly while the harmful energy drops. No muffled cotton-in-the-ears that tempts them to pull it out.
Molded to the ear
A seal that holds all shift and disappears in the ear. Comfort is what turns a rating on paper into protection on the floor.
Built strong to last
Hand-built in our South Carolina lab to survive years of real shifts — not a single one. Product no competitor has the patents or process to make.
20 years, family-run
The same people who started this in 2003 still answer the phone. Two decades of integrity behind every fitting — Strength and Honor is how we build.
Never caught in confusion
One rep. One number. Zero runaround.
The hardest part of most safety programs is reaching a human who can actually help. Not here. You get a dedicated account rep who knows your facility by name — and a service model built around your schedule, not ours.
A dedicated account rep
One person who knows your floor, your areas, and your reorder cadence. Reachable directly — no ticket queue, no phone tree.
On-site fitting events
We come to you and take impressions of your entire crew in a single visit. Minimal downtime, every ear captured on the record.
Easy impression kits
Prefer to fit at your own pace? We ship impression kits with prepaid return shipping — take impressions at your discretion and mail them back.
Perfect-Fit Promise
If a plug doesn’t seal right, we remake it — free. A worker’s protection is never left to “close enough.”
Fast reorders & new-hire fittings
Onboard a new hire or replace a lost pair without restarting the process. Your records stay current and your program stays covered.
Documentation that stands up
Records organized for your hearing-conservation program — clean for audiogram reviews and OSHA logs.
Where we fit your program
Built to slot into your hearing conservation program.
OSHA 1910.95 puts the whole program on your desk — monitoring, audiometric testing, protection, training, and records. You keep the parts only you can own. Big Ear takes the part where most programs quietly fail: protection that’s actually worn, fit the right way, and documented.
Protectors that get worn
The NRR you specify only counts if it’s on the ear all shift. Custom fit closes the gap between the number on paper and the dB at the eardrum.
A fit you can stand behind
Every plug is molded to the individual and sealed to their ear. No roll-and-squeeze to get wrong, no derated foam to explain.
Training at the fitting
Your rep fits each worker and teaches insertion, care, and wear in the same visit — a documented training touchpoint, handled on-site.
Records that hold up
Per-worker documentation, organized for audiogram reviews and your OSHA log. You walk into the audit prepared.
Coverage that never lapses
New hires fitted, lost pairs replaced, remakes free under the Perfect-Fit Promise. Your program stays current between audits.
You keep exposure monitoring and audiometric testing. We own the protection that keeps those audiograms from moving.
Run your facility’s numbers
See the five-year math on your own floor.
Custom looks more expensive on day one. Across the life of the program — with plugs that last years and actually get worn — the picture flips. Put your numbers in; the arithmetic is yours to check.
Or tap your facility size
This tool compares direct spend only. It does not price in the larger avoided costs — standard threshold shift follow-ups, workers’ comp claims, and turnover — which is where custom protection pays for itself.
What fits your floor
The right plug depends on the job.
Situational awareness on one line, maximum quiet on another, radio comms on a third. We match the product — and the attenuation — to each area, not to a one-size box.
Hear the floor. Block the harm.
Flat, even attenuation with interchangeable filters — 9, 15, 20, 25, or 30 dB. Standard ($224.95, one filter), Select ($299.95, two), Premium ($574.95, all five).
Best for: comms-critical & variable-noise areas
Maximum, steady quiet.
Full-block custom plugs for high, constant noise — Full Stop and Lab-Generated Solid tiers. Nothing to fumble, nothing to fall out.
Best for: high steady-state noise floors
Sealed to the ear.
Molded to each worker and sealed the same way every shift — comfortable enough they forget it’s in. That’s the only reason a plug actually gets worn, and worn is the only thing that protects.
Best for: every worker on the program
The right protection per zone.
Interchangeable filters from 9 to 30 dB let your rep tune attenuation to each area — situational awareness where it matters, maximum block where it’s loudest. One program, dialed in per floor.
Best for: multi-area facilities
The honest comparison
Foam, pre-molded, or built to the ear.
The right column is the only one that protects a worker who’s uncomfortable, distracted, and eight hours into a shift — because it’s the only one they keep in.
| Disposable foam | Pre-molded / one-size | Big Ear Custom | |
|---|---|---|---|
| Real-world attenuation | Derated hard — insertion-dependent | Better, but a generic seal | Sealed to each ear, consistent |
| All-shift comfort & wear | Low — comes out by mid-shift | Moderate | High — molded to the ear |
| Hear speech & alarms | Muffled | Limited | Yes — The One® flat attenuation |
| Lifespan | One shift | Months | Years — 36-month warranty on on-site made |
| Cost over time | Re-bought forever | Recurring | One-time, then reorders |
| Hygiene | Handled repeatedly | Shared-fit risk | Sani-cast™ / Sani-mold™ — no transfer |
| Fit & records | None | None | Per-worker, documented |
See it work
Proof, not promises.
Walkthroughs of exactly what a rollout looks like and why the fit holds. [Video placeholders — drop in final footage.]
Pricing & value
Custom costs less than you think — and far less than the alternative.
A custom plug that lasts years and actually gets worn beats a disposable pair thrown out daily and worn wrong. That’s the direct cost. The real return is in what you stop paying for.
- Fewer standard threshold shifts and the follow-ups they trigger.
- Fewer noise-induced hearing-loss claims — each one is expensive and permanent.
- Higher wear rates, fewer complaints, and a program leadership can see working.
- Facility and volume pricing — the more of your crew you protect, the lower the per-worker rate.
The long game
A hearing-conservation partner, not a vendor.
This isn’t a one-time purchase order. It’s a program we run alongside you — from the first walkthrough to every new hire, year after year.
Assessment
Your rep walks the floor, maps exposures by area, and recommends the right product and attenuation for each — not one plug for the whole building.
On-site fitting
One coordinated visit. We mold every ear in your program with minimal disruption to the line.
Deployment
Labeled, color-coded, and documented for your program. Every worker in the right protection, on the record.
Ongoing service
New-hire fittings, fast reorders, and free remakes under the Perfect-Fit Promise. Your coverage never lapses.
Documentation & review
Clean records for audiogram reviews and OSHA logs — and a rep who’s a phone call away when you need them.
For the person who owns this
You brought this in. We make you the one who got it right.
The hardest safety wins to defend are the ones no one can see. A hearing program is different when it’s working — you can hear it on the floor and show it on the log. We build the rollout so it makes you look exactly as good as it is.
Start with an assessment- A turnkey rollout you can hand to leadership as a finished plan, not a project you have to babysit.
- Wear rates that climb because the crew is comfortable — the metric that actually moves your audiograms.
- Fewer noise complaints and grievances, and a visible signal that safety spent the money well.
- Documentation ready for review — you walk into the audit prepared, not scrambling.
- One rep who makes you look responsive because you always have an answer.
Straight answers
What every EHS officer asks first.
How do you make sure each worker gets the right protection?
We match the product and attenuation to each area of your floor, then mold the plug to the individual ear. The seal is the fit — there’s no roll-and-squeeze technique to get wrong and no derated foam to account for. Your rep confirms the seal at the fitting.
How does this fit our OSHA hearing conservation program?
We provide the hearing protectors, the individual fit, a documented training touchpoint at the fitting, and per-worker records. You keep exposure monitoring and audiometric testing — we own the protection that keeps those audiograms from moving, and hand you clean documentation for review.
How fast can we roll this out across a facility?
On-site solid earplugs are made while the worker waits — about an hour per person — so a crew can be fitted in a single coordinated visit. Impression-based products run 35–40 business days from the day impressions reach our lab. We’re transparent about that timeline up front; the fit is why it’s worth it.
Is it hygienic for a shared industrial environment?
Every custom plug is made with our Sani-cast™ material and Sani-mold™ process, so there’s no transfer of bacteria between impressions. Each worker’s protection is molded from their own ear and belongs to them alone.
What’s the warranty, and how do we handle new hires and lost pairs?
On-site made earplugs carry a 36-month warranty. New-hire fittings and fast reorders keep your coverage current, and anything that doesn’t seal right is remade free under the Perfect-Fit Promise. Your program never has a gap waiting on a replacement.
What does it cost for a facility?
Per-worker pricing runs below single-unit rates at volume, and your rep builds a facility quote after the assessment. Use the planner above to see the five-year picture on your own headcount — and remember it doesn’t yet count the threshold shifts and claims you avoid, which is where custom pays for itself.
What documentation do we receive for our program and an OSHA audit?
Per-worker records of who received which device, the device specifications for your file, and a training sign-off captured at the fitting — organized so your audiogram reviews and OSHA 1910.95 logs are clean and defensible.
Will workers still hear alarms and each other?
Yes — that’s the whole idea behind The One. Its flat-attenuation filters lower harmful noise evenly while preserving speech and warning signals, and your rep matches the filter to each area so you’re not over-isolating the crew. Workers stay aware, which is exactly why they keep the plugs in.
Is the material safe for all-day skin contact?
Every plug is medical-grade silicone made with our Sani-cast™ material and Sani-mold™ process — biocompatible, non-porous, built for a full shift against the skin, with no bacteria transfer between impressions.
Can we pilot it before rolling out facility-wide?
Yes. Start with one line or department — fit a group, run it a few weeks, and fit-check the results before you commit the whole facility. It’s the low-risk way to prove wear rates and protection to your leadership.
Can you handle a large workforce or multiple sites?
Yes. On-site fitting events scale to your entire crew, and we coordinate multi-site rollouts and reorders through one dedicated rep — so a program that spans buildings or states still runs through a single point of contact.
Turn exposure into a plan
Book a facility assessment.
Tell us about your floor. Your dedicated rep follows up within one business day to schedule a walkthrough or an on-site fitting event — and to build your facility quote.