Canal Caps vs Ear Plugs - Best Hearing Protection PPE - X1 Safety

Canal caps vs earplugs: Choosing the right hearing protection

Protecting your hearing isn’t optional—it’s essential. In noisy workplaces like construction sites, factories, and maintenance zones, consistent exposure to high decibel levels can lead to permanent hearing loss. But with so many hearing protection options available, how do you choose what’s right for your team?

This guide compares two common types: canal caps and earplugs. We’ll break down how they work, their pros and cons, and which environments they’re best suited for, so you can make informed decisions that protect your workforce and meet safety regulations.

Canal caps vs earplugs: which hearing protection should you choose

While earplugs and ear muffs offer hearing protection for work environments with loud noise levels, canal caps are a convenient type of hearing protection specifically for work environments with moderate daily average noise levels, where hearing protection is only needed for short periods of time.

Canal caps have rounded heads that cover the entrance to the ear canal. These flexible tips act as caps that plug the ear canal. They only close the ear opening and do not extend deep into the ear canal. The flexible foam tips are attached to a headband which can hang around your neck when not in use.

Semi-insert earplugs are very similar to canal caps. According to the Institution of Occupational Safety and Health (IOSH), semi-insert earplugs generally have conical tips that are pushed into the ear canal.

Both canal caps and semi-insert earplugs are convenient for situations where hearing protection must be taken on and off frequently and quickly. However, they generally do not provide as much protection as foam or custom earplugs.

Earplugs are also used to prevent hearing loss. These devices are inserted into the ear to reduce the level of sound reaching the inner ear (cochlea). While earplugs offer a tighter seal and block more sound than canal caps, they can be less convenient to insert and remove.

According to the National Institute for Occupational Safety and Health (NIOSH),
“The main advantage canal caps offer is convenience. When it’s quiet, employees can leave the band hanging around their necks. They can quickly insert the plug tips when hazardous noise starts again. Some people find the pressure from the bands uncomfortable. Not all canal caps have tips that adequately block all types of noise. Generally, the canal caps tips that resemble stand-alone earplugs seem to block the most noise.”

Canal caps: pros and cons
Shop canal caps

Canal caps and headband hearing protector semi-insert earplugs provide hearing protection against moderate daily average noise levels in work environments where hearing protection is only needed on an intermittent basis. Canal caps may be used to block out nuisance noises. To wear canal caps, insert the tips of the caps into the ear, firmly wiggling them into place.

Pros:

Canal caps are easy to insert. They are ideal for people going in and out of noisy areas. As they can hang around your neck on a band while not in use, this makes them more convenient to use and more difficult to lose when not in use. Canal caps can be easier to use than pre-molded ear plugs.

Cons:

Canal caps are only partially inserted into the ear canal, therefore they do not provide as much of a seal inside the ear canal as ear plugs. This means that canal caps do not provide as much noise reduction as foam earplugs or earmuffs. Because they are reusable, they may not be as sanitary as disposable earplugs. Firm pressure from the headband is required to maintain an effective seal which means that the headband can become uncomfortable with long use.

Canal caps may have a noise reduction rating (NRR) as low as 25dB. Some – though not all – earplugs and ear muffs have an NRR of 30-33dB. Canal caps are not recommended for use on job sites with continuous exposure to loud noise above 80 decibels.

Earplugs: pros and cons
Shop reusable earplugs

Formable or foam earplugs will expand to fill the ear canal and seal against the walls (when placed in the ear correctly). This expansion allows foam ear plugs to fit ear canals of different sizes. Formable earplugs are usually sold in bulk as a one-size-fits-most hearing protective device.

Pre-molded ear plugs come in different sizes and shapes to fit different-sized ear canals. Pre-molded reusable earplugs are available with or without a cord.

Pros:

Expandable foam earplugs are inexpensive and disposable, making them a sanitary option (when properly used). Certain types of pre-molded and formable ear plugs can offer excellent hearing protection for work environments with noise levels exceeding 85 decibels.

Cons:

Foam formable ear plugs require an ear mold impression; if not properly inserted, the amount of noise reduction is reduced. They can also be difficult to quickly remove. If you remove earplugs too quickly, you could irritate your ear canal or even damage your eardrum.

Reusable pre-molded ear plugs have virtually no expansion or contraction, so obtaining a good seal with the ear canal may be challenging. Again, improper insertion can reduce noise reduction rating value. If not properly cared for, reusable earplugs can be unsanitary, increasing the risk of ear infections.

If you need to remove your hearing protection often, ear plugs might not be the best hearing PPE option. In that case, industrial ear muffs are a better option for a highly protective, non-invasive hearing device that can be quickly removed. However, the effectiveness of ear muffs depends on how tight the seal is between the foam cushion and the head.

Type	Features	Concerns
Roll down foam	Fits many differently shaped ear canals. Provides good protection for most noisy environments. Convenient, disposable.	Must be inserted properly to get the highest possible protection. If the plug doesn’t make a good seal, it won’t protect your hearing.
Reusable earplugs	Many have flanges and handles. Come in different sizes. Come with cords, convenient to carry. Reusable. Washable.	Preformed so may not fit as wide a variety of ear canals as foam plugs. May require a different size for each ear. Must keep them clean.
Custom moulded	Molded to the user’s ear. Always comfortable. Long-termwear. Best for difficult-to-fit ears.	Must be made by a licensed hearing protection provider.
Canal caps	On a band, can be worn under the chin, over the head, or behind the neck. Can be put on and taken off quickly.	Not as comfortable as other devices. Not as much protection as other devices.
Earmuffs	Easy to use and wear. Fit most people. Easy to keep clean.	Can be hot and heavy. May be more difficult to get a good fit with glasses and/or may interfere with other protective gear.
New type Flat Attenuated Communication	Flat reduction of noise overall frequencies. Have a baffle to reduce impact noise. Radio Communication while still reducing noise.	Can be expensive. Must be custom fitted.