Safe maintenance – packaging manufacturer in court over workplace injury

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Packaging manufacturer in court over workplace injury

A supplier of corrugated packaging has been fined £400,000 after a maintenance employee was injured when he was pulled into machinery.

The injured person was repairing a cardboard printing, slotting and forming machine at the packaging plant when he put his foot onto an exposed conveyor and was dragged into the machine’s moving parts.

Wolverhampton Crown Court heard that the packaging company allowed uncontrolled maintenance work to take place without any assessment of the risks posed by maintenance activities or having procedures in place for safe maintenance.

A Health and Safety Executive (HSE) investigation found that the machinery had a ‘jog mode’ which could have been set up to enable such maintenance work to be carried out safely, but the company had not identified this, trained staff to use it or enforced its use.

Speaking after the case, HSE Inspector Caroline Lane said: “The company relied on the experience of maintenance employees rather than controlling risks through careful assessment and putting safe systems of work in place.

In summing up, his Honour Judge Berlin considered the maintenance practices used by [the packaging company] to be ‘utterly dangerous’ and the risk to workers was wholly avoidable”.

Safe maintenance

Hazards during maintenance

What is maintenance?

In this context, maintenance simply means keeping the workplace, its structures, equipment, machines, furniture and facilities operating safely, while also making sure that their condition does not decline. Regular maintenance can also prevent their sudden and unexpected failure.

There are two main types of maintenance:

  • preventive or proactive maintenance – periodic checks and repairs; and
  • corrective or reactive maintenance – carrying out unforeseen repairs on workplace facilities or equipment after sudden breakage or failure. This is usually more hazardous than scheduled maintenance.

Why is it an issue?

Maintenance-related accidents are a serious cause of concern. For example, analysis of data from recent years indicates that 25-30% of manufacturing industry fatalities in Great Britain were related to maintenance activity.

Undertaking maintenance activities can potentially expose the workers involved (and others) to all sorts of hazards, but there are four issues that merit particular attention because of the severity of the harm that could be involved, and because they are commonly encountered during plant and building maintenance.

The health consequences of disturbing asbestos when drilling holes into the building fabric or replacing panels can be severe, as can the clean up costs involved.

Maintenance work often involves using access equipment to reach roofs, gutters, building services, and raised sections of plant and machinery. It can be all too easy to fall from these positions, or to drop things onto people beneath.

Isolation and lock off arrangements, and in some cases permits to work, are essential to enable maintenance work to be conducted safely.

Heavy items sometimes have to be moved, or get disturbed, during maintenance work. If one of these falls, the results can be fatal. There may well be cranes, fork lift trucks or props available for use, but maintenance tasks can sometimes involve one-off situations and the handling of heavy loads isn’t always properly planned.

You may do some or most of your plant and building maintenance in-house, but there will always be tasks that are too big or specialised and require contractors. To enable both in-house and contracted staff to work in safety you will need to properly brief them on your site and processes, and you will need them to follow safe working practices.

For more information, visit the HSE web page: or contact us on 07896 016380 or at, and we’ll be happy to help

Contains public sector information published by the Health and Safety Executive and licensed under the Open Government Licence



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