2025 PPE Pain Points Study: key trends and challenges in workplace safety

In March 2025, J. J. Keller & Associates, Inc., in collaboration with the International Safety Equipment Association (ISEA), released the findings of their third annual "PPE Pain Points Study: Top Trends and Challenges." The study examines the current state of personal protective equipment (PPE) management, highlighting both progress and persistent challenges in the purchasing and use of PPE.

While the study found that 95 percent of respondents have adequate time and resources to assess PPE needs effectively, employee compliance remains a significant hurdle. Although 70 percent indicated they discuss PPE regularly with employees, 75 percent reported difficulties in ensuring that employees consistently wear PPE. Year over year, compliance issues remained consistent, with the most common reasons for non-compliance related to individual employee preferences: workers don't want to wear PPE (56 percent), they don't think it's needed (48 percent) and it makes the job more difficult (36 percent). Unlike other issues such as comfort (34 percent) and improper fit (16 percent), the top reasons cannot be resolved with changes in procurement.

Training is key to educating employees on when and what PPE is necessary, but over one-half of the respondents find it challenging to train employees in this aspect of PPE usage. This suggests a need for improved training programs and resources. Almost two-thirds of employers allow employees to choose PPE from an existing inventory, while 49 percent assign PPE based on size.

When selecting PPE, durability emerged as the top priority, with over one-third of respondents emphasizing its importance. Comfort closely followed, underscoring the importance of enhancing employee compliance. While most organizations did not have issues in procuring PPE sizes, those facing challenges highlighted difficulties in finding larger and smaller sizes. More organizations prioritize PPE designed for women, but one-third encounter challenges finding options that fit properly. Cost and managing inventory are other common challenges.

Environmental issues, particularly weather conditions, are an emerging concern in PPE selection, with 84 percent considering it when purchasing PPE. To combat heat and cold, companies most commonly offer employees electrolyte beverages, winter gloves, raincoats, and cooling scarves or towels. There's a recognized need for more education on selecting PPE optimized for extreme temperatures.

When employees purchase their own PPE, almost 94 percent of the respondents have specific requirements or guidelines, including validating with management, purchasing from select vendors or certain types of PPE, or adhering to guidelines.

For the first time this year companies were asked how they measure the effectiveness of their PPE program. 63 percent said they use incident and injury rates, and 54 percent rely on employee feedback, both lagging indicators. The top leading indicator was measuring employee compliance rates (41 percent).

Moving forward: enhancing PPE programs

The findings from the 2025 PPE Pain Points Study underscore the importance of continuous improvement in PPE programs to strengthen compliance. Organizations are encouraged to:

• Enhance training programs: Develop compelling training to ensure employees understand the importance of PPE and how to use it correctly. Combine hands-on practice and interactive elements, with clear communication. Visual demonstrations and real-world scenarios emphasizing the consequences of not using it properly can also enhance learning. Include regular refresher courses.
• Focus on comfort and fit: Invest in PPE that offers durability and comfort, catering to a diverse workforce with varying sizing needs. Involve workers in the decisions.
• Consider environmental factors: Select PPE suitable for the specific environmental conditions employees face, particularly extreme temperatures.
• Clarify PPE terminology: Provide clear information on the differences between various types of PPE, such as hard hats and helmets, to reduce confusion and ensure proper usage.
• Establish clear policies and enforce them consistently: Make it clear that PPE is mandatory and not optional. Follow through with disciplinary action for non-compliance.