Moldex 6534 SparkPlugs EcoStation XL Refill — NRR 33dB, 750 Pairs

Moldex SparkPlugs — NRR 33 dB Foam Earplug, Metal Detectable Option Available

The Moldex SparkPlugs is a NRR 33 dB disposable foam earplug distinguished by its vivid multicolor foam body and the availability of a metal-detectable compound version — the only earplug in the Moldex lineup engineered specifically for facilities where earplug loss into product is a regulatory or food safety concern. Available as the 6604 uncorded, 6654 corded, and 6615 metal detectable corded, plus EcoStation, PlugStation, and TouchFree dispenser formats for high-volume programs. For a no-roll-down foam alternative with the same NRR, see the Moldex Pura-Fit (NRR 33). For SparkPlugs in a PlugStation metal detectable dispenser, see the 6881 PlugStation metal detectable dispenser.

Key Features

• Metal-detectable compound — engineered for food and pharmaceutical lines: The SparkPlugs 6615 is the standout option in this family — a NRR 33 corded foam earplug with metal-detectable compound embedded throughout the foam body. If an earplug or foam fragment enters a production line, standard metal detection and X-ray inspection equipment will trigger a product reject — satisfying the earplug detectability requirements of HACCP, BRC, SQF, and customer-mandated food safety programs
• High-visibility multicolor foam — compliance monitoring at a glance: The SparkPlugs' neon multicolor pattern is visible from a distance in plant environments — safety managers and supervisors can verify worker compliance without approaching each workstation. In high-throughput manufacturing where visual compliance checks happen multiple times per shift, the SparkPlugs' color contrast over skin tones and work clothing is a genuine operational advantage
• NRR 33 — maximum single-device attenuation: At NRR 33, SparkPlugs deliver the highest protection rating available from a foam earplug — sufficient for environments up to approximately 103 dBA TWA when properly worn (effective attenuation of 13 dB after OSHA 50% derating). This satisfies OSHA 1910.95 requirements across the vast majority of general industry noise environments
• Latex-free and PVC-free formulation: SparkPlugs foam contains no latex, PVC, chloroprene, or other common sensitizers — making them appropriate for latex-allergic workers and for industries with strict PPE material restrictions on products that contact workers' bodies
• Full dispenser ecosystem: SparkPlugs are available in the complete Moldex dispenser format lineup — EcoStation (6703), PlugStation uncorded (6644, 6645), PlugStation corded (6880), PlugStation metal detectable (6881), and TouchFree EcoStation (6833) — enabling implementation at any facility scale and hygiene requirement level

Applications — When to Use Moldex SparkPlugs

• Food processing and packaging (metal detectable — specify 6615): Meat processing, bottling, bakery, dairy, and packaged goods production lines frequently mandate metal-detectable PPE under HACCP or retailer-specific food safety standards. The SparkPlugs 6615 satisfies these requirements at NRR 33 — the highest attenuation available in a metal-detectable earplug format. For dispenser programs on metal-detection-monitored lines, the 6881 PlugStation metal detectable dispenser provides bulk distribution
• Pharmaceutical manufacturing: Tablet compression, packaging, and process areas with noise levels 90–105 dBA and strict contamination control requirements — the SparkPlugs' clean material formulation and metal-detectable option (6615) address both hearing protection and loss-into-product concerns in cGMP-regulated environments
• General manufacturing and assembly: Press rooms, stamping lines, CNC machining, and assembly environments in the 90–103 dBA range — SparkPlugs NRR 33 provides maximum attenuation, and the high-visibility multicolor body aids the compliance monitoring required under OSHA hearing conservation programs
• Construction and infrastructure: Jackhammering, concrete cutting, heavy equipment, and demolition — the corded 6654 keeps both plugs accessible when workers move between noisy and quiet areas, and the bright coloration remains visible even in PPE-dense environments
• High-volume industrial programs with dispenser infrastructure: The SparkPlugs PlugStation (6644/6645 uncorded, 6880 corded, 6881 metal detectable) and EcoStation (6703) systems support facility-wide dispenser programs — mount at area entrances to eliminate barriers to hearing protection compliance

SparkPlugs — All Variants

SparkPlugs vs. Competing NRR 33 Foam Earplugs

OSHA Compliance & Hearing Conservation

Moldex SparkPlugs are rated under ANSI S3.19-1974 at NRR 33. Under OSHA 29 CFR 1910.95, SparkPlugs are appropriate hearing protection for workers with TWA noise exposures from 85 dBA to approximately 103 dBA (OSHA 50% derating applied). For food processing facilities, the 6615 metal-detectable variant satisfies the earplug detectability requirements of HACCP, BRC, and SQF food safety programs in addition to OSHA 1910.95 hearing protection requirements.

• Correct insertion technique is critical: OSHA 1910.95(i)(4) requires training on hearing protector use — roll-down foam earplugs achieve labeled NRR only when fully compressed and held in the ear canal until foam fully expands. Workers who do not compress fully or do not hold the plug in place may receive significantly less than 13 dB effective attenuation
• Metal-detectable food safety compliance: 6615/6881 contain metal-detectable compound engineered to trigger standard metal detection equipment — consult your facility's food safety program to confirm detection threshold requirements are met
• Annual audiometric testing: Required under OSHA 1910.95(g) for all workers in a hearing conservation program — hearing protection selection and training should be documented as part of the written program required under 1910.95(c)

Frequently Asked Questions

What is the NRR of Moldex SparkPlugs?

SparkPlugs (6604/6654/6615) have NRR 33 dB. Effective attenuation under OSHA's 50% derating: (33 – 7) × 0.5 = 13 dB. In a 100 dBA environment, estimated ear exposure = 87 dBA with proper insertion.

What makes SparkPlugs different from other Moldex foam earplugs?

The key differentiators are the vivid multicolor foam for easy compliance monitoring and the metal-detectable compound option (6615 corded, 6881 PlugStation dispenser) for food processing and pharmaceutical facilities. The SparkPlugs are also one of the few NRR 33 earplugs with a dispenser program that includes a metal-detectable format.

What is the SparkPlugs 6615 metal detectable earplug?

The 6615 is a corded NRR 33 SparkPlug with metal-detectable compound embedded throughout the foam body. If the earplug or a foam fragment enters a production line, it will trigger metal detection or X-ray inspection equipment — satisfying food safety program requirements under HACCP, BRC, SQF, and customer specifications.

Are Moldex SparkPlugs latex-free?

Yes — latex-free, PVC-free, and chloroprene-free. Appropriate for latex-sensitive workers and for facilities with material restriction requirements on PPE that contacts workers' bodies.

What is the difference between 6604, 6654, and 6615?

6604 is uncorded (200 pairs per bag). 6654 is corded (100 pairs per bag). 6615 is metal-detectable and corded — specifically for food/pharma lines with metal detection. All three use identical NRR 33 SparkPlugs foam.

How do I insert SparkPlugs correctly?

Compress the foam to a thin cylinder between clean fingers. Reach over or around the head with the opposite hand to pull the outer ear up and back. Insert the compressed earplug with a slow twisting motion and hold for 20–30 seconds while the foam expands. The outer end should be flush with the ear canal opening — not protruding significantly. Incomplete compression or not holding the plug during expansion are the most common fit errors.

Can SparkPlugs be used in food processing?

Standard 6604/6654 SparkPlugs are bright-colored but not metal-detectable. For facilities with metal detection or X-ray inspection on product lines, specify the 6615 metal detectable corded earplug or the 6881 PlugStation metal detectable dispenser. Both are PVC-free and latex-free.

What dispenser options are available for SparkPlugs?

Full dispenser ecosystem: EcoStation 6703 (500 pairs wall-mount), TouchFree EcoStation 6833 (no-contact dispensing), PlugStation 6644 (250 uncorded), PlugStation 6645 (500 uncorded), PlugStation 6880 (150 corded), PlugStation 6881 (150 metal detectable corded), and jar format 6684 (50 uncorded).

How do SparkPlugs compare to Pura-Fit?

Both are NRR 33, latex-free, PVC-free Moldex foam earplugs. Pura-Fit (6800) uses no-roll-down insertion — better for dirty/gloved-hand environments. SparkPlugs (6604) requires roll-down compression. SparkPlugs has the metal-detectable option (6615); Pura-Fit does not. For most programs, either is appropriate — choose SparkPlugs 6615 when metal detection is required.

Do I need to fit test earplugs?

OSHA does not require individual earplug fit testing. However, OSHA 1910.95(i)(4) requires training on selection, fitting, use, and care. Proper insertion technique is critical — actual attenuation in practice is determined almost entirely by correct fit, not by labeled NRR alone.

Where can I buy Moldex SparkPlugs in bulk?

WC Safety stocks 6604 uncorded (200 pairs), 6654 corded (100 pairs), 6615 metal detectable corded, jar 6684 (50 pairs), all EcoStation and PlugStation dispenser formats. Browse the Moldex Earplugs collection at WC Safety →