Laminator Cleaning Accident Leads To Prosecution

Brief Summary

A manufacturing employer was prosecuted after a laminator operative suffered a severe crush injury when their hand was pulled into the nip point between rollers during cleaning. The regulator found no fixed guard and inadequate risk assessment and safe system of work for cleaning tasks. The case reinforces the need to assess non production activities and to prioritise engineering controls under the Provision and Use of Work Equipment Regulations 1998.

What Was The Incident?

On 17 January 2025 at a site in Telford a laminator operative and shift supervisor was cleaning the rollers of a laminating machine using rags after a production run. A rag became caught between two in running rollers and pulled the worker's left hand into the nip point up to the wrist. A colleague used the emergency stop to free the hand. The worker sustained a severe crush injury, underwent two operations, spent four nights in hospital and later required physiotherapy to rebuild strength in the injured hand. An investigation by the Health and Safety Executive found the employer had not provided a fixed guard to prevent access to the dangerous nip point during cleaning. The regulator also found the employer's risk assessment and safe system of work were not suitable and sufficient. The cleaning operation had not been properly assessed and the safe system did not give clear instructions about using the foot pedal to rotate the rollers during cleaning.

What Was The Outcome?

The employer pleaded guilty to breaching Regulation 11(1) of the Provision and Use of Work Equipment Regulations 1998. The company was fined £60000  and ordered to pay £4464 in costs at Birmingham Magistrates Court on 10 August 2026. This follows a separate sentencing in November 2025 relating to a fatal incident at another site where the same employer was fined £277500.

Key Points To Consider

Fixed guards for dangerous nip points. Verify that fixed guards or other engineering controls prevent access to in running rollers during cleaning and maintenance and that guards cannot be readily removed for routine cleaning; apply the hierarchy of control in PUWER and give priority to permanent barriers where reasonably practicable.

Risk assessments and safe systems for cleaning. Review risk assessments to include cleaning maintenance and repair as foreseeable tasks and ensure safe systems of work set out how the machine is isolated, who is authorised to operate controls such as a foot pedal and what steps must be taken before anyone approaches moving parts.

Training isolation and emergency procedures. Confirm staff and supervisors are trained in correct cleaning methods, machine isolation and emergency stop use, and keep records of training and of any medical follow up after incidents so controls can be revised where needed.

HSE Prosecution Link