A global glass bottle manufacturer, O-I Glass Limited, has been fined £600,000 after a worker suffered scald burns from molten glass and hot water spilling into his vehicle cab.
The incident occurred at the company’s Glasshouse Loan site in Alloa on 3 February 2024. The 32-year-old employee was operating a shovel loader to clear waste molten glass and hot water from the basement floor of the site, which employs around 500 people. During this task, molten glass and hot water spilled from the loader’s bucket into the cab, causing burns covering 8 percent of his body. Fortunately, the worker has since made a full recovery.
An investigation by the Health and Safety Executive (HSE) found that the protective door on the loader’s cab had been missing since March 2022. This door, which included a glass window for protection, was removed after being damaged, and although the issue was reported to a site engineer, no action was taken to replace it for nearly two years. During this period, other workers reported being struck or having their footwear burnt by molten glass entering the cab.
O-I Glass pleaded guilty to breaches of the Provision and Use of Work Equipment Regulations 1998 and the Health and Safety at Work etc Act 1974, specifically failing to maintain the vehicle in an efficient, safe, and good working order. The company was fined at Stirling Sheriff Court on 23 September 2025.
After the accident, the loader was removed from service until June 2024, when it returned equipped with a steel front door featuring a protective glass window with wire mesh.
HSE Inspector Kathy Gostick said: “This was an avoidable ordeal for a young worker. It is sheer luck he has been able to recover from his serious injuries. The company’s employees operated in a hazardous environment with a safety-critical part of the loader missing for almost two years. Despite reports to engineers, the loader was used without the protective door, exposing workers to danger. Proper risk assessments and suitable equipment maintenance are essential to prevent such incidents.”
What it means for HSE managers
This case highlights the critical importance of performing thorough risk assessments on work equipment and ensuring all safety features are maintained. HSE managers should:
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Verify that all vehicles and machinery are equipped with appropriate protective structures suited to the working environment.
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Ensure damaged safety equipment is promptly repaired or replaced.
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Monitor and enforce compliance with equipment maintenance regulations.
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Recognize that failure to maintain equipment adequately can lead to severe injury and costly prosecutions.
