I have used Mack’s ThermaFit earplugs for a few years.
They have been my go-to recommendation for low frequency noise (LFN) reduction foam earplugs ever since Flents changed the formula of their Quiet Please.
Foam earplugs that are good at reducing LFN and comfortable at night are hard to come by, yet can make all the difference against heavy traffic, music bass, AC hums, etc.
Unfortunately, I have been receiving reports that Mack’s has changed their formula as well, stating that the earplugs are now much bigger and that the material has changed.
On their website, they are now advertised as having an NRR of 30 (previously 29) and retailers state “New Upgraded and Improved.”
I decided to get a small pack—10 pairs of the improved formula (I will call them v2) to compare them to the old formula (v1). (I still have quite a few of the old formula left from previous orders.)
Contents
Size and material differences between v2 and v1
As you can see in the title image, the new earplugs are substantially longer (on avg. 21.4 mm vs 19.8mm for v1).
They also have a tad smaller diameter and the edge where they have been cut feels a bit less smooth.
Unlike some reports to the contrary, the v2 are still PVC foam earplugs (so not higher density PU plugs as the new Quiet Please).
Comparison (diameter and length as per my calipers):
Looking at the substantial length increase, I can see why folks who liked the original formula and have a shorter ear canal might find them uncomfortable.
Also, there is a much wider length variation within the same batch than before.
Rolling them up, the length difference appears to be even more pronounced compared to the old formula.
They expand slower than v1. This is actually an advantage because they give you more time to insert them.
ThermaFit v2 vs original formula (at the bottom) after about the same expansion time.
It is quite clear that the foam composition has also changed (still PVC but somewhat different).
They are still very effective at reducing low frequency noise.
In my ear, they initially feel comfortable and low pressure, but the length is a bit of a problem.
If I insert them so they feel and appear at the same depth from outside the ear, they start hurting after a while.
The solution is to let them protrude more.
Still, towards the end of a night they start hurting. I often sleep on my side so my pillow might push them in, leading to discomfort.
I could use these for a night if I had to, but definitely find them less comfortable than the old formula. They are not ideal anymore for me for sleeping.
Given the v2 are still good at reducing low frequency noise, they could perhaps be an option for someone with a very long ear canal.
Daytime use
I also used them during the day and can keep them in for 8 hours. Again, I find them less comfortable than v1, but decent for day-time use.
All in all
The new Mack’s ThermaFit are still very good at reducing low frequency noise, which many earplugs don’t do in my ears. On the other hand, for night-time use they are not quite comfortable enough for me. I think most people who liked the original formula will do better with the EAR Classic detailed in the next section.
If, however, you have a very long ear canal and found the original formula too short, the v2 might still be an option for you.
What can you do if Mack’s ThermaFit v2 doesn’t work for you anymore?
In response to my results, I ordered a new batch of the grandfather of all PVC foam earplugs, 3M’s yellow EAR Classic.
In the past, I had the feeling they were a bit harder than ThermaFit and Quiet Please, but the batch I got this time works great!
They are almost the same size and appear to have the same (or almost the same) foam composition as the ThermaFit v1.
Comparison table (length and diameter as per my calipers):
I have now used them for multiple nights without any issues.
They feel as comfortable as ThermaFit v1 and are effective at reducing noise, including low frequency noise.
Note: The similarity in foam composition surprised me a bit, so I dug out a couple of old Classic from an order a few years ago. Indeed those feel harder and are shorter (19.1mm). It’s difficult to go back in time, but maybe that batch was already old when I got it?
In any case, the current batch of EAR Classic works very well for me. I prefer them over the new ThermaFit.
So, if you struggle with new ThermaFit formula, but loved the old one, try 3M’s EAR Classic.
What could Mack’s do to make ThermaFit v2 work better?
Reverting back to v1 would be my preferred solution.
But suppose they don’t have access to the original supplier/material anymore. There is no guarantee that everyone will like the new foam material.
However, on the plus side, the earplugs are still made of PVC and I felt they were fairly low pressure in my ear. Moreover, the LFN reduction performance of ThermaFit v2 is still very good.
If Mack’s were considering refinements to the design, I would recommend they:
Reduce the length back to 19.8 mm at most (as per my measurement of v1).
Ensure there is as little length variation between earplugs as possible.
If possible, make the edges a bit smoother.
Note: Given that the foam composition is somewhat different, comparing the rolled-up length could perhaps yield additional insight.
