Key Features

• Dual-mode protection: Rotate the stem to switch between NRR 20 (closed, maximum protection) and NRR 10 (open, situational awareness mode). No removal needed to switch modes.
• Impulse noise attenuation in open mode: The open position uses a non-linear acoustic filter that attenuates high-intensity impulse sounds (gunshots, explosions, impacts) while allowing lower-level sounds like speech and commands to pass. This is passive acoustic filtering — no batteries or electronics required.
• Replaceable tip system: The stem and housing are reusable; only the foam-tipped insert is replaced. Replacement tip sets (sold separately) extend the life of the BattlePlug housing indefinitely.
• Size XS fit: BattlePlugs come in four sizes (XS, S, M, L) to accommodate different ear canal diameters. Proper size selection is critical to achieving rated NRR — do not use an incorrect size.
• Corded: Included neck cord keeps the pair accessible during rapid transitions between protection modes or when earplugs are temporarily removed.
• No batteries: Passive acoustic design — no electronics, no charging, no failure risk in field conditions.

Closed vs. Open Mode — When to Use Each

In open mode, the acoustic filter passes steady-state sounds at or below conversational levels while mechanically limiting the peak pressure of sudden high-intensity sounds. This is not electronic noise cancellation — it is a passive valve design. As a result, open mode is most effective for impulse-type noise rather than sustained industrial noise above the Action Level.

Applications

• Military and law enforcement: Original design application — allows operatives to communicate while protected against muzzle blast, breaching charges, and other impulse noise.
• Firearms training ranges: Switch to closed for sustained fire strings; open for range commands, safety briefings, and target assessment between strings.
• Hunting: Open mode preserves game-hearing acuity while protecting against muzzle blast on the shot — critical for hunters who cannot predict when a shot will occur.
• Demolition and construction: Open mode for intermittent impact tools; switch to closed for sustained equipment operation.
• Industrial maintenance: Workers entering and exiting noise zones — open while walking and communicating, closed during actual equipment operation.

Sizing Guide — Choosing the Right BattlePlug Size

BattlePlugs require proper size selection to achieve rated NRR. An undersized earplug will not seal; an oversized earplug will be uncomfortable and may not insert fully. Available sizes:

If unsure of size, most adults fit S or M. Start with M; if the earplug does not seat fully or feels oversized, try S. XS is intended for small adult ear canals. L is for larger-than-average canals. The foam tip should compress slightly on insertion and form a firm seal without forcing.

BattlePlug vs. Alternatives

NRR 20 Noise Reduction (Closed Mode) — Environmental Context

OSHA 29 CFR 1910.95 Hearing Conservation Compliance

BattlePlugs are ANSI S3.19-rated hearing protectors and satisfy OSHA 29 CFR 1910.95 hearing protection requirements when used in the closed position and when the rated NRR provides adequate attenuation for the measured TWA noise level. Key points for compliance programs:

• Use the closed position (NRR 20) for OSHA TWA calculations — do not use open-mode NRR for compliance purposes in sustained-noise environments.
• Apply OSHA 50% derating: effective = (NRR 20 − 7) ÷ 2 = 6.5 dB(A). This earplug protects to 97 dB(A) TWA (single protector, closed mode).
• Open-mode NRR 10 is appropriate for impulse noise environments where peak pressure — not TWA — is the primary hazard. For MIL-STD-1474 and DoD impulsive noise guidelines, consult your safety officer.
• Proper size selection is mandatory for achieving rated NRR. Include BattlePlug sizing fitting in employee training.

Frequently Asked Questions

Is BattlePlug Size XS right for me?

BattlePlugs come in XS, S, M, and L to fit different ear canal diameters. Size XS is designed for small adult ear canals — if standard earplugs are too large or uncomfortable, try XS first. Insert the earplug — it should seat firmly with the outer flange flush to the canal opening. If it seats loosely or falls out, try a larger size. If it cannot be fully inserted, try a smaller size.

How is the open-mode acoustic filter different from electronic hearing protection?

The BattlePlug open mode is entirely passive — it uses a mechanical valve and acoustic pathway that physically limits peak sound pressure without any electronics. This means no batteries, no delay between sound and protection, no failure risk due to dead batteries in the field, and no electronic artifacts in the sound. The tradeoff is that passive open-mode NRR (10) is lower than what electronic level-dependent earmuffs can achieve. For law enforcement or military use where battery failure is unacceptable, BattlePlugs are often preferred over electronic alternatives.

When should I replace the foam tips?

Replace the foam tips when the foam no longer compresses and re-expands consistently, when the tip surface is visibly contaminated (earwax, debris that cannot be cleaned), or when the tip has been used for the equivalent of 30+ shifts. Replacement tip sets are sold separately — see the BattlePlug replacement tips in the Moldex Earplug Collection. The stem housing is designed to last indefinitely with tip replacement.

Can I use BattlePlugs for industrial OSHA compliance?

Yes — in the closed position, BattlePlugs satisfy OSHA 29 CFR 1910.95 hearing protection requirements when NRR 20 (effective 6.5 dB(A)) is adequate for the measured noise exposure. Apply the standard 50% derating. For environments requiring higher attenuation, the Moldex SparkPlugs or Pura-Fit with NRR 33 (effective 13 dB(A)) provide better single-protector coverage. BattlePlugs are particularly useful in facilities where workers need to communicate during the shift without removing hearing protection.

Can I use the combo pack to try different sizes?

The Moldex BattlePlug Combo Pack (SKU 6598) includes one BattlePlug unit and one pair of Moldex SparkPlugs NRR 33 in a single package — it is not a multi-size sampler. For sizing trials, purchase individual units in each suspected size and test insertion and seal before committing to bulk quantities. Most adults find their correct size on the first or second try by starting with M and adjusting.