Mallory Is Your Trusted Source for Kappler Chemical Protective Suits

Hazmat calls send techs toward hazards they can’t see, and their suits have to hold. Kappler makes chemical protective suits for those crews, including the Zytron® 500 and the Frontline® 500.

We’ve served public safety for 45 years, and our goal at Mallory is simple: every hazmat tech goes home safe at the end of a shift. In 2025 alone, agencies from the Midwest to the West Coast turned to our Public Safety Team for Kappler hazmat suits. Tell us about your hazmat calls, and we’ll help you choose the right suit.

To see more about our dedication to safety for Fire and EMS Teams, click here.

35+ Nationwide Locations. Dedicated Public Safety Team.
Serving First Responder Squads for 45 Years.

Compliant Procurement and Grant Deadline Support

Outfit one tech or an entire team with Kappler chemical protective suits. Our Public Safety Team helps you match the suit to the hazard and size it across your department. Our service centers handle fit testing and pressure testing. Cooperative purchasing lets your agency piggyback on a contract that has already been awarded, so you can meet grant deadlines and keep your procurement fully compliant. Call 800-MALLORY or click here to explore options for your agency.

Top-Level Protection for Demanding Hazmat Response

Your hazmat team shouldn’t have to second-guess its suit. Zytron® 500 is built with gas-tight vapor styles and splash styles for liquid hazards. In fabric testing, it held out for more than eight hours against all 21 chemicals in the ASTM F1001 battery. It also held out for more than eight hours against four chemical warfare agents: mustard (HD), sarin (GB), Lewisite (L), and VX.

Gas-Tight Closures, Visor, and Gloves

Vapor styles close with an AquaSeal® gas-tight zipper and carry two exhaust valves. An AntiFog expanded-view visor system comes standard on gas-tight styles, including NFPA-certified styles. Hazmat styles have seams that are sewn, then double heat sealed and taped.

Hazmat styles include the 2N1® glove system, which eliminates inner glove inversion, and vapor styles have attached, field-replaceable gloves.

Technical Specifications

• Greater than 8-hr holdout against hundreds of chemicals
• ASTM F1001 battery, 15 liquids and 6 gases: all above 480 minutes, tested on
  fabric samples
• Chemical warfare agent permeation (total cumulative permeation, fabric samples): mustard (HD), sarin (GB), Lewisite (L), and VX each above 480 minutes
• AntiFog expanded-view visor system, standard on gas-tight styles, including NFPA-certified styles
• SMART™ label with QR code for sizing, chemical data, and suit details
• Total encapsulating suit and coverall styles, including vapor, splash, overhood, and training styles
• NFPA 1990 (1994) Class 2 and NFPA 1990 (1992) styles available
• Sizes: SM/MD, LG/XL, 2X/3X, 4X

NFPA 1990 (1991) Apparel for Chemical Flash Fire Protection

Frontline® 500 is a vapor total encapsulating suit for hazmat response and chemical handling where a chemical flash fire is possible. It meets NFPA 1990 (1991), including the optional Flash Fire and Liquefied Gas requirements. In fabric testing, 20 of the 21 chemicals in the ASTM F1001 battery held out for more than eight hours. The one exception, dichloromethane, held out for 253 minutes.

Where Frontline 500 Fits on the Scene

Frontline® 500 is a chemical and hazmat response suit designed for escape only in the event of a chemical flash fire. Unless otherwise indicated, no Kappler products are intended as fire protection or for use in firefighting applications, open flame or intense heat. We want you to know that before the order, because a responder should never find a suit’s limits on scene.

Download the Kappler Frontline® 500
Product Overview Here

Technical Specifications

• 48" AquaSeal gas-tight zipper for easier donning, doffing, and pressure testing, with double storm flaps and FR hook-and-loop closure
• Removable overglove and field-replaceable 2N1 glove system
• SMART™ label with QR code for sizing, chemical data, and suit details
• Multi-use, single exposure
• ASTM F1001 battery, 15 liquids and 6 gases, tested on fabric samples: 20 of 21 above 480 minutes, dichloromethane at 253 minutes
• Chemical warfare agent permeation (total cumulative permeation, fabric samples): mustard (HD), sarin (GB), and VX above 480 minutes, Lewisite (L) above 240 minutes
• NFPA 1990 (1991) certified, including the optional Flash-Fire and Liquefied Gas requirements, front-entry and rear-entry vapor total encapsulating styles
• Sizes: SM/MD, LG/XL, 2X/3X, 4X

Why Choose Mallory as Your Procurement Partner for Kappler Suits?

Mallory is the largest independent safety distributor in the US. We've served hundreds of fire departments, hazmat teams, and rescue squads across all 50 states for 45 years. You can look to us to supply, repair, and callibrate your critical equipment through our 35+ stocking locations and 10 service centers.

Shop the Kappler Line of Protective Clothing

We're an authorized Kappler distributor with access to their line of protective apparel. Your agency can count on us to have the depth and availability to help you implement a department-wide rollout without chasing inventory across multiple vendors. Kappler suits come in multiple styles, entry types, and sizes.

Public Safety Team with Hazmat Experience

Our dedicated Public Safety Team supports public safety agencies outfitting for hazmat, CBRN, and drug response. We can walk you through the levels of chemical suit protection and help you match each suit to the hazards your teams expect to enter. If the garment you need requires configuration to your application, tell us how your team will use it and we’ll help you build the right order.

Comprehensive Solutions to Ease Your Daily Operations

Convenient, Compliant Procurement

As a contract holder under OMNIA Partners Public Safety, we offer a compliant piggyback path onto a contract that has already been competitively solicited and publicly awarded by a lead agency.

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Pressure Testing Service

Rely on our Service and Repair Team to help with Level A and B chemical protective suit testing. You'll receive recordkeeping documentation for your audits and accreditation reviews.

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HAZWOPER Training

Our expert Training Team can instruct your staff on donning and doffing, working in limited-visibility encapsulated suits, and understanding the operational constraints of high-level chemical protection.

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Frequently Asked Questions

How can I check a Kappler suit’s sizing and chemical data?

Each Zytron® 500 and Frontline® 500 suit carries a SMART™ label that puts sizing in plain view. A quick QR code scan pulls up complete chemical data and suit details.

Are Kappler suits intended for structural firefighting?

No. Kappler suits are hazmat and chemical response garments. Kappler states that, unless otherwise indicated, no Kappler products are intended as fire protection or for use in firefighting applications, open flame or intense heat. Review the label and product page for each suit before you specify it, and call our team if you want a second set of eyes on your selection.

What is the difference between permeation and penetration of chemical hazards?

Permeation is the movement of a material through barrier fabric on a molecular level. Penetration is the bulk movement of a material through a pore, gap, or defect in the barrier fabrics.

What is OMNIA Partners and how could it simplify our purchasing process?

OMNIA Partners is a cooperative purchasing organization. It runs competitively solicited, publicly awarded contracts on behalf of a lead public agency, and then makes those contracts available to other government agencies nationwide who want to compliantly “piggyback” onto them to help meet tight grant deadlines.