Supervisor Severely Injured After Entering Live Palletiser

Brief Summary

A supervisor entered the area of a palletiser to clear a blockage after a damaged interlocking gate made normal access difficult. A loose panel was removed, the conveyor restarted when a sensor was triggered and the worker was struck by machine pushers. The case shows the consequences of allowing guarding and interlock systems to become insecure and of normalising work around damaged safety equipment.

What Was The Incident?

During routine production a palletiser developed frequent blockages. Staff found the interlocking safety gate difficult to open after the gate locking mechanism had been damaged by a forklift earlier in the year. Rather than isolate the machine before intervention, senior staff removed a loose panel and entered the machine area. As the supervisor walked along the stationary conveyor to clear the blockage he triggered a sensor which restarted the machine. He was struck repeatedly by the palletiser pushers. He received multiple fractures to ribs pelvis clavicle and scapula, two collapsed lungs and was airlifted to hospital where he required intensive and high dependency care. HSE inspectors found perimeter fencing and the interlock had become insecure and that staff had repeatedly bypassed the gate instead of isolating power and reporting the defect.

What Was The Outcome?

The employer pleaded guilty to breaching Regulations 11(1) and 11(2) of the Provision and Use of Work Equipment Regulations 1998 and section 33(1)(c) of the Health and Safety at Work etc. Act 1974. At court the company was fined £420000 and ordered to pay a victim surcharge of £31500 giving a total financial penalty of £451500. The employer reported the incident to the regulator on the day it happened and subsequently reinstated the perimeter fencing so the gate is the only means of accessing the machine and updated site rules to make clear that staff must not bypass safety barriers.

Key Points To Consider

Maintain guarding and interlock integrity. Check physical guards interlock function and locking mechanisms as part of routine maintenance. Repair damaged panels fittings or locks immediately and verify that any interlock opening isolates power before allowing access.

Require positive isolation before entry. Review procedures to make isolation the default for any intervention inside machine enclosures. Make sure staff understand and can follow lockout and isolation steps and that there are clear consequences for bypassing safety barriers.

Address repeat blockages and unsafe workarounds. Investigate frequent stoppages to reduce the need for hands on intervention. Use task observation audits near miss reporting and supervisor checks to detect and stop informal workarounds and to confirm that safe systems are followed on the shop floor.

HSE Prosecution Link