A North Yorkshire manufacturing firm has been hit with a substantial fine after a night shift worker died in a preventable workplace accident. There were critical lapses in safety procedures, and this case study serves as a stark reminder of the risks associated with inadequate safeguarding and insufficient fall protection.
The Incident:
On the night of 11 February 2023, 51-year-old man was working a shift at a paper sack manufacturer located in Stamford Bridge near York. While operating a production line, a blockage occurred on the upper level of the machinery. The worker attempted to clear the obstruction by standing on stationary metal rollers. During this process, part of the machine unexpectedly activated. He was struck by the moving equipment, lost his footing, and fell approximately three metres from the unguarded edge to the factory floor. Emergency services were called, but he was pronounced dead at the scene.
The Investigation:
A subsequent inquiry by the Health and Safety Executive (HSE) revealed that the paper sack manufacturer had failed to implement a safe system of work for dealing with machinery blockages and failed to assess or mitigate the risks of working at height. The investigation uncovered that staff regularly cleared jams without proper isolation procedures and had not received sufficient training. Workers were also found to be using conveyor belts as shortcuts between platforms, climbing over handrails instead of using stairs – practices that management personnel were unaware of. These actions expose workers to significant hazards and breach safety regulations.
The Outcome:
At Hull Magistrates’ Court on 30 April 2025, the company pleaded guilty to breaching Section 2(1) of the Health and Safety at Work Act 1974. The company was fined £533,000 and ordered to pay £6,066 in legal costs. HSE Inspectors emphasised that the fatality could have been avoided if proper isolation and fall prevention measures had been in place. He noted that a significant number of workplace fatalities continue to result from inadequate protection around machinery and unsafe practices at height.
Implement Safe Working at Height with Sentient
Falls from height remain the leading cause of workplace fatalities in the UK. On average, 50 workers lose their lives each year due to falls (2024 statistics show an increase), with many more suffering life-changing injuries such as paralysis, brain trauma, and multiple fractures.
Sentient, partners of Romero Insurance, provide advice and guidance on effective Health & Safety implementation for businesses. Sentient’s risk management services are primed to help businesses avoid falls from height, or becoming case studies such as the above. To learn more about our services or talk to their team, contact us.
Sentient have provided some Key Safety Reminders for Working at Height, they include:
- Risk Assessments & Planning – Identify and control hazards before starting work.
- Fall Protection – Use harnesses, lanyards, and secure anchor points.
- Proper Training – Ensure workers are competent and receive refresher training.
- Equipment Inspections – Regularly check scaffolding, ladders, and PPE.
- Emergency Planning – Have a rescue plan in case of a fall or equipment failure.
