Intersnack's journey to comprehensive hearing protection
The invisible threat: why hearing protection matters
Noise-induced hearing loss (NIHL) is the most common, permanent, and irreversible workplace injury in the world. Every day, millions of employees are exposed to hazardous noise levels, often without realising the long-term consequences.
In the UK alone, 11,000 cases of work-related hearing problems have been reported annually since 2020, with 85 cases of occupational deafness recorded in 2022. Unlike visible injuries, hearing damage happens progressively and is often unnoticed until it is too late.
Beyond its invisibility, hearing loss presents another challenge: not all hearing protection is effective just because it is worn. Earplugs, for example, must be correctly inserted and properly fitted to provide adequate protection, yet most workers do not insert them correctly. Additionally, hearing protection is not one-size-fits-all. Each individual’s ear canal is unique, some smaller, some wider, meaning a poorly fitted earplug can significantly reduce its effectiveness.
Overprotection is another often-overlooked issue. As production plants modernise, machinery becomes quieter, requiring lower levels of noise attenuation. Using earplugs with too high attenuation can hinder communication and situational awareness, increasing the risk of accidents. Frustrated workers may remove their earplugs to communicate, ultimately defeating the purpose of wearing protection in the first place.
Intersnack’s commitment: going beyond legal compliance
Recognising these challenges, Intersnack, a leading manufacturer in food industry with multiple production sites across Europe, decided to take hearing protection to the next level. Instead of merely meeting regulatory requirements, they committed to a proactive approach, ensuring their employees received the best possible protection tailored to their needs.
Like many companies in the manufacturing industry, Intersnack faced common hearing protection challenges. Poor fitting was a widespread issue, preventing employees from receiving the intended level of protection. With a high share of women in production roles, standard earplug sizes often failed to provide adequate protection for those with smaller ear canals. Overprotection was another challenge, employees were using high SNR (>30 dB) earplugs in environments where noise levels ranged from 80 to 95 dB, making communication difficult and limiting the ability to recognise important signals. In quieter areas (<80 dB), employees who wished to use hearing protection found existing options unsuitable due to excessive noise reduction.
The uvex solution: A tailored hearing protection programme
To tackle these challenges, Intersnack partnered with uvex to implement a comprehensive hearing protection programme. This included:
uvex xact-fit detec earplugs
Employees were equipped with uvex xact-fit detec earplugs, designed for optimal fit and ease of use. These earplugs provided the appropriate level of noise protection without impairing communication and situational awareness. The uvex xact-fit earplugs featured an ergonomically shaped pin, enabling quick, precise insertion even when wearing gloves. By offering two earplug size options, uvex ensured that all employees, regardless of ear canal size, could achieve a secure and comfortable fit.
uvex xact-fit test
The uvex xact-fit test system was introduced to verify whether employees were receiving the intended level of protection. This easy-to-use system identified fitting issues and helped select the right earplug size for each worker. The test system also served as an educational tool, raising awareness about the importance of proper hearing protection and empowering employees to take their safety into their own hands.
Conclusion: A model for workplace hearing protection
Through proactive investment in a tailored hearing protection programme, Intersnack demonstrated a strong commitment to employee well-being. By addressing the key challenges of overprotection, poor fit and awareness, they not only enhanced workplace safety but also set a benchmark for other manufacturers to follow. Hearing protection is not just about compliance, it’s about safeguarding one of our most vital senses. Thanks to this collaborative effort, workers across multiple sites can now perform their jobs safely, comfortably and with confidence in their long-term hearing health.
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