Factory Services UK has been fined £160,000 after a worker suffered what the Health and Safety Executive (HSE) described as “catastrophic, life-changing injuries” when his arm was pulled into an unguarded conveyor.
A subsequent HSE investigation found that the company had been allowing employees access to dangerous parts of machinery for many years at its facility in Knowsley Industrial Park.
The incident occurred on 18 March 2025, when maintenance engineer Daniel Slinger was working a night shift and was asked to investigate an issue with a conveyor.
Slinger reached through a hole in the side of the conveyor casing while the machine was running to clear away material.
His arm was then pulled into the moving machinery. There was no guard in place and no emergency stop button in the area.
This was despite the company’s own safe systems of work requiring machinery to be guarded and isolated before any maintenance or cleaning activity was carried out.
Slinger, who was working alone on site at the time, attempted to raise the alarm by waving at a CCTV camera.
No one came to his aid, and he was eventually able to free his arm after 40 seconds. He suffered extensive injuries to his forearm and hand, including a fracture and significant degloving injuries.
Slinger required multiple operations and blood transfusions and continues to receive specialist treatment. He remains unable to return to work.
Investigators found that the hole had been cut into the conveyor several years earlier to allow workers to clear blockages while the machine remained in operation. A second conveyor on site was also found to have a similar unauthorised access point.
Despite routine inspections, management walkarounds and audits, the dangerous modifications had not been identified or rectified.
Following the incident, the manufacturer fitted a fixed mesh guard and installed an emergency stop button at the location.
Factory Services UK Limited pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974 at Warrington Magistrates’ Court on 8 September 2026. The company was fined £160,000 and ordered to pay costs of £4,728.
Following the hearing, HSE inspector Ian Betley said: “Mr Slinger suffered devastating and life-altering injuries as a result of this preventable incident. Had the correct protections been in place he would not have been exposed to the dangerous parts of a running conveyor through a hole cut into the machine.
“Factory Services UK Limited had risk assessments and safe systems of work, but they were not followed or enforced. Employers must ensure guarding is properly maintained, safe systems are implemented, and workers are protected from foreseeable risks.”
