Factory Services UK Limited, a Merseyside animal-feed manufacturer, has been fined £160,000 after one of its maintenance engineers suffered catastrophic, life-changing injuries when his arm was drawn into an unguarded conveyor. The incident occurred on 18 March 2025 at the company’s site on Moorgate Road, Deacon Park, Knowsley Industrial Park, with the firm sentenced on 8 September 2026 at Warrington Magistrates’ Court.
Unguarded conveyor traps engineer, causing severe arm and hand damage
The Health and Safety Executive (HSE) investigation revealed that Factory Services UK Limited had permitted workers access to dangerous parts of machinery for many years. On the night of the incident, maintenance engineer Daniel Slinger was working alone when he was tasked with addressing an issue on a conveyor belt. While the machinery was still operational, Mr Slinger reached through an unapproved hole in the side of the conveyor casing to clear an obstruction.
His arm was immediately pulled into the moving machinery. Crucially, there was no guard in place to prevent access to the dangerous parts, nor was an emergency stop button available in the immediate vicinity. Trapped and alone, Mr Slinger desperately waved at a CCTV camera, hoping someone monitoring the system would spot his predicament and come to his aid. However, no one responded. After approximately 40 seconds, he managed to free his arm from the machinery.
Mr Slinger sustained injuries to his forearm and hand, including a severe fracture and extensive degloving. These injuries necessitated multiple operations and blood transfusions, and he continues to receive specialist medical treatment. The severity of his injuries has rendered him unable to return to work, profoundly impacting his life and livelihood.
The HSE’s investigation further uncovered that the dangerous hole had been cut into the conveyor years prior to the incident. This modification was made to facilitate the clearing of blockages while the machine remained in operation, a practice that directly contravened the company’s own safe systems of work, which mandated machinery guarding and isolation before any maintenance or cleaning. A second conveyor on the site was also found to have a similar, unauthorised access point. Despite routine inspections, management walkarounds, and audits, these dangerous modifications had not been identified or rectified by the company.
Following the incident, Factory Services UK Limited implemented corrective measures, installing a fixed mesh guard and an emergency stop button at the location of the incident. The company pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974. In addition to the £160,000 fine, the company was ordered to pay costs of £4728.
HSE Inspector Ian Betley commented on the case, stating: “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.” He further emphasised, “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.”
This prosecution underscores the critical importance of adhering to health and safety regulations, particularly concerning machinery guarding and maintenance procedures, to prevent serious workplace injuries.
This story was originally published by HSE Media Centre.
