As the world continues to deal with various airborne illnesses and hazards, the need for respiratory protection has become more critical. When considering which respirator is right for you, the first decision to make is whether you should use a disposable or reusable respirator. In this article, we’ll compare the differences between disposable and reusable respirators to help you decide which choice is best for both your safety and budget.

Single-use Disposable Respirators

Properly fitted disposable N95 respirators are designed to protect you from harmful airborne particulates, including non-oil and oil-based aerosols such as silica, wood dust, and viruses like COVID-19.

They are typically made of a filtering material that consists of multiple layers of polyethylene outer and inner shell. The filtering part of an N95 disposable respirator is often made of a spun-bonded melt-blown material that captures airborne particles and protects the wearer from inhaling harmful aerosol-based particulates.

Disposable Respirators: Cost Considerations

Disposable respirators are not available in multiple sizes, and as a result, the fitting capabilities on a wide range of facial features and sizes are poor. In a study conducted by the Journal of American Medical Association (JAMA), they outfitted 100 EMS team members with disposable N95 respirators and another 100 with reusable N95 respirators. When the EMS participants conducted simulated patient treatments, the disposable respirators had a failure rate of 36%, while the participants using the reusable respirators did not have any failure rates.  

When Should You Use a Disposable Respirator?

Disposable respirators are suitable for people who need short-term protection and will be using them in areas where the risk of infection or exposure is low. However, disposable respirators are not designed to last long, and are not suitable for repeated use.

Recommended Applications:

Construction and Manufacturing: Disposable respirators are used in construction and manufacturing industries where workers are exposed to dust, fibers, and other airborne particles. These respirators are lightweight and easy-to-use, making them ideal for workers who need to move around frequently.

Home Improvement Projects: Disposable respirators can also be useful for home improvement projects around the house where a respirator may be needed for short periods of time.

Reusable N95 Respirators

As the name suggests, a reusable respirator is like a long-term relationship; it can be used over and over, and you only need to replace the filter when needed.

There is a misunderstanding on how to clean a respirator and how long this process takes. However in the time it takes to wash your hands properly at the end of the day, you can also clean and disinfect your respirator daily.  Many manufacturers sell disinfecting wipes that allow the user to quickly wipe down the respirator.  This is one of the recommended processes.

• Wipe the inside of the respirator first. As this is the part that has been on the face. Wipe the inside of the mask and the sealing area.
• Using the same wipe, or another wipe, clean the outside of the mask. This will remove any direct, paint or chemicals on the outside of the mask. 
• Store the mask in a bag and the cartridges in another bag.
• Now you have a freshly cleaned and disinfected respirator ready for use the next day.

Unlike disposable respirators, reusable respirators are designed to be reused multiple times and last for a long time. They typically consist of a facepiece made of durable elastomeric rubber material, such as silicone or thermoplastic rubber, that creates a more effective and consistent seal around the face, preventing air from leaking around the edges into the mask. It offers a much tighter and safer seal than disposables. Plus, they can withstand repeated use due to the durable material.

Reusable Respirators: Cost Considerations

Reusable respirators have a higher upfront cost than disposable respirators, causing some people to believe that using one is more expensive, but the total cost of ownership must be considered first. It is important to remember that with less consumption comes less cost, which is why reusable respirators are much more sustainable. Swapping out disposables for reusable respirators in high-volume settings like hospitals and certain industrial applications can reduce waste by millions of pound annually. It will also reduce incineration costs for those that dispose of the mask and help to lower carbon emissions.

Reusable respirators last significantly longer than disposables because the filter is encapsulated in a protective housing. A half mask, made of durable elastomeric rubber, can last for years with proper maintenance.

Reusable respirators also have replaceable filters that can be changed when they become loaded or damaged. You can easily switch out the filters/cartridges on your reusable N95 mask depending on the application and hazard. So, whether you need an N95 filter for silica dust or an OV/P100 for paint vapor, you only need one mask; just switch out the filters. Be sure to use Dentec’s Guide to Selecting the Right Respiratory Protection to choose the right cartridges/filters for the job.

Dentec’s N95 and P100 filters can be disinfected and reused for one year (depending on usage) when protecting against a virus, contributing to a 95% reduction in waste and a 90% cost savings versus disposable respirators.

Reusable Respirators: Safety Considerations

Reusable respirators come in different types, such as half-mask and full face mask. They are known to be more comfortable than disposable respirators and can be customized to fit the user’s face more precisely. If you must wear a respirator for extended periods of time, reusable respirators are surprisingly cooler than their disposable counterparts. According to internal temperature recording inside Dentec’s masks, they are two degrees cooler than disposables.

Reusable N95 respirators are also easier to breathe through than disposable respirators. Inhalation and exhalation testing shows that Dentec’s respirators reduced breathing resistance by more than 50%.

Reusable respirators come in various sizes to offer a better fit and seal for all face shapes and sizes. Dentec’s line of reusable half-mask respirators come in various sizes including small, medium, and large. They also come in two different structural designs for the sealing surface of the respirator, which are anatomically shaped differently to fit a wide variety of facial features and sizes.  

When Should You Use a Reusable Respirator?

Medical and Healthcare Settings: Disposable respirators are widely used in medical and healthcare settings where the risk of exposure to airborne particles and infectious diseases is high, and healthcare workers must dispose of N95s between patient interactions. Reusables can just be cleaned and reused, resulting in less waste and lower costs. According to the CDC, a reusable respirator that uses an N95 or P100 filter can used for up to a year for protection against a virus such as COVID-19. Other indicators to change the filter are when it becomes difficult to breathe, or it becomes soiled or wet.

Agriculture and Farming: Reusable respirators are also used in agriculture and farming industries where workers are exposed to dust, mold, and other airborne particles. These respirators are designed to be durable and long-lasting, making them ideal for use in outdoor and harsh environments.

Chemical and Pharmaceutical Manufacturing: Reusable respirators are commonly used in chemical and pharmaceutical manufacturing, where workers are exposed to hazardous chemicals and vapor. These respirators are designed to be comfortable and easy to use, while also providing a high level of protection against airborne particles and vapors.

Discover the Dentec Difference

Dentec Safety offers three different series of reusable respirators to choose from:

100 Series – Silicone Rubber:

• The 100 Series silicone rubber adjustable mask is molded from pure silicone, making it comfortable and easy to clean. The textured ‘no-slip’ face seal and large flexible sealing edge provide a better fit.
• Our multi-position cartridge attachment offers fitting options that improve visibility and provide great compatibility with other PPE.
• The extra-large inhalation valves are uniquely designed with a plenum space between the filtering material and the inhalation port. Inhaled air is evenly distributed across the filter which lowers breathing resistance and extends cartridge life.
• Made in America.

300 Series Thermoplastic Rubber:

• This thermoplastic rubber mask provides excellent comfort and durability.
• The 300 series features only nine replacement parts, flexible sealing edge and a multi-position cartridge attachment for a comfortable fit, longer lifetime, and move savings.
• The extra-large inhalation valves and unique corrugated exhalation value diaphragm moves more hot air out of the mask more easily.
• Made in America.

400 Series Elastomeric Rubber:

• The 400 series elastomeric rubber mask combines outstanding value with a high-quality product.
• This molded elastomeric mask features a flexible sealing edge and a multi-position cartridge attachment to ensure better comfort, fit, and productivity.
• The extra-large exhalation valve and unique, corrugated exhalation valve moves hot air out the mask easily, allowing you to breathe easier and use the mask for longer.
• Made in America.

The choice between disposable and reusable respirators depends on your safety needs and budget. Disposable respirators are suitable for short-term use, while reusable respirators are ideal for long-term protection. If you need to use a respirator regularly, a reusable respirator is the best option. Despite the initial higher cost, the long-term savings are much more cost-effective, and more importantly, they offer a high level of protection because they can secure an airtight seal. However, if you only need a respirator for occasional use, a disposable respirator may be the more cost-effective solution. Ultimately, choosing the right respirator is essential for protecting yourself from airborne hazards and ensuring your safety in hazardous environments.

Dentec Safety is a leading manufacturer and distributor of safety products in the North America since 2004. Dentec Safety is dedicated to providing the highest quality safety products and solutions delivering enhanced value and comfort. Our expertise from decades of experience in Industrial Safety and our innovative design technologies have solidified us as thought leaders in the field. Protection and comfort are at the core of everything we do at Dentec. As a leading manufacturer of Safety Solutions, it is our mission to help organizations do the right thing, keep their employees safe and exceed Industry Health & Safety Standard.