A Merseyside animal feed manufacturer has been fined £160,000 after a maintenance engineer suffered severe injuries when his arm was drawn into an unguarded conveyor.
Daniel Slinger was working a nightshift at Factory Services UK Limited’s site in Knowsley Industrial Park when the incident occurred in March 2025.
Mr Slinger suffered extensive injuries to his forearm and hand and has been unable to return to work.
Engineer trapped in moving conveyor
Mr Slinger had been asked to investigate an issue with a conveyor when he reached through a hole in the side of its casing to remove material while the machinery was still operating.
His arm was pulled into the moving equipment. The Health and Safety Executive (HSE) found there was no guard covering the access point and no emergency stop button in the immediate area.
Mr Slinger was working alone and nobody was nearby to see or hear what had happened.
He attempted to attract attention by repeatedly waving towards a CCTV camera, but nobody responded. After approximately 40 seconds, he was eventually able to free his arm.
Life changing injuries sustained
Mr Slinger suffered a fracture and extensive degloving injuries to his forearm and hand.
He required multiple operations and blood transfusions and continues to receive specialist treatment.
The company’s own safe systems of work required machinery to be guarded and isolated before maintenance or cleaning activities were undertaken.
Access point had existed for years
HSE’s investigation established that the hole in the conveyor had been created several years earlier to allow workers to clear blockages while the equipment remained operational.
A second conveyor at the site was found to have a similar unauthorised access point.
Despite routine inspections, management walkarounds and audits, HSE found that the modifications had not been identified or rectified.
Following the incident, Factory Services UK Limited installed a fixed mesh guard and an emergency stop button at the location.
Company fined £160,000
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 £4,728 in costs.
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.”
