A Merseyside animal-feed manufacturer has been fined £160,000 after a maintenance engineer suffered catastrophic injuries when his arm became trapped in an unguarded conveyor while investigating a fault during a night shift. [press.hse.gov.uk], [hse-network.com]
An investigation by the Health and Safety Executive (HSE) found that Factory Services UK Limited had allowed workers access to dangerous parts of machinery for many years at its site on Knowsley Industrial Park. [press.hse.gov.uk], [feedstrategy.com]
On 18 March 2025, maintenance engineer Daniel Slinger was asked to investigate an issue with a conveyor. While the machinery was still operating, he reached through an unauthorised opening in the conveyor casing to clear a blockage. His arm was pulled into the moving equipment. Investigators found there was no guard in place and no emergency stop button nearby. [press.hse.gov.uk], [internatio…ournal.com]
Working alone, Mr Slinger had no immediate assistance and repeatedly waved at a CCTV camera in an attempt to attract attention. After approximately 40 seconds, he managed to free himself from the machinery. He suffered severe injuries, including a fracture and extensive degloving injuries to his forearm and hand. Multiple operations, blood transfusions and ongoing specialist treatment have been required, and he remains unable to return to work. [press.hse.gov.uk], [healthands…ybuyer.com]
The HSE investigation revealed that the access hole had been cut into the conveyor several years earlier to allow workers to clear blockages while the machine continued running. A second conveyor on site was found to have a similar modification. Despite inspections, audits and management walkarounds, the dangerous alterations were not identified or corrected. [press.hse.gov.uk], [hse-network.com]
At Warrington Magistrates’ Court, Factory Services UK Limited pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974. The company was fined £160,000 and ordered to pay £4,728 in costs. [press.hse.gov.uk], [internatio…ournal.com]
Following the hearing, HSE Inspector Ian Betley said the injuries were entirely preventable and highlighted the importance of ensuring machinery is properly guarded, isolated and maintained in accordance with established safety procedures. [press.hse.gov.uk], [healthands…ybuyer.com]
Key Safety Message: Machinery guarding, lock-off procedures and effective supervision are critical controls that help prevent serious workplace injuries. Employers must ensure risk assessments and safe systems of work are not only in place but actively followed and enforced. [healthands…ybuyer.com], [press.hse.gov.uk]
Source: Health and Safety Executive (HSE) press release, September 2026. [press.hse.gov.uk]
