Food processing is a loud industry that, in many cases, necessitates hearing protection for workers. During an 8-hour shift in a food processing plant, workers are routinely exposed to noise surpassing 85 decibels (dB), the level at which the Occupational Safety and Health Administration (OSHA) requires hearing protection be made available. Ear plugs are the most common hearing protection for employees, but their small size presents a risk of loss, which in a food processing environment is also a contamination risk. A lost ear plug can find its way into food being prepared or packaged, leading to a damaging recall or at the very least, a time-consuming search for the missing item. That’s why metal-detectable ear plugs are an ideal choice for food processing employees.

Maintaining a safe food processing environment is vital at a time of increasing food recalls. An analysis issued by the U.S. Food and Drug Administration (FDA) and United States Department of Agriculture (USDA) from 2020-2024 shows that 11.6% of all recalls were due to contamination from foreign objects.

When it comes to necessary personal protective equipment (PPE), making the right choice is not just about protection, but also about how well it fits the task. Some types of hearing protection may not be appropriate for a food processing environment. For example, disposable ear plugs are especially prone to being misplaced. Ear muffs may interfere with other PPE or sanitary coverings like hairnets. Corded ear plugs are designed for the plug to detach from the cord for safety reasons, which can mean a lost plug or cord. Metal-detectable ear plugs, however, are designed with food industry conditions in mind.

How do metal-detectable ear plugs work? There’s a small metal component built into the plug, such as a stainless-steel bead in the plug or stem, that can be quickly identified by metal detectors. Most food manufacturing facilities use metal detection as a standard element of their quality testing, meaning that a lost ear plug can be found before it becomes a larger problem. Even corded versions may have metal particles within the cord so that it can also be detected if lost. Some facilities also use x-ray technology in identifying contaminants, which can spot these ear plugs.

While metal-detectable ear plugs are an ideal match for a food processing facility’s existing contamination testing, proper use, fit, and design should not be overlooked. Conducting fit testing will help ensure that a worker’s ear plugs are not so small that they accidentally fall out nor so tight that they become uncomfortable. Having a variety of styles on hand will help employees find a pair that’s a good fit for them. And brightly colored options will make visual inspection easier so that metal detection isn’t the only reliable method for finding lost ear plugs.

The usefulness of metal-detectable ear plugs is not limited to food processing. Any industry where product contamination is a potential risk can benefit from them. Facilities in the pharmaceutical and cosmetic industries, among others, may want to consider this style of hearing protection.