Packaging manufacturer fined £20,000 after worker loses finger to unsafe machinery

Film & Foil Solutions Ltd, a manufacturer in the flexible packaging sector, has been fined £20,000 following a severe injury sustained by an employee at its Haydock Industrial Estate facility. Film & Foil Solutions Ltd is widely recognised as one of the UK’s leading converters and stockists of flexible packaging films. The incident occurred on December 4, 2023, when a worker was operating a machine designed for converting and folding plastic film. To prevent material entanglement, the employee attempted to manually halt a rotating shaft that was inadequately guarded. In doing so, his right index finger made contact with a moving part of the machinery, leading to entanglement.

The injured worker was immediately taken to the hospital. Due to the critical nature of the injury, he underwent surgery the following day to amputate part of his dominant right index finger. In a statement provided to the Health and Safety Executive (HSE), the employee, who wished to remain anonymous, described the profound impact of the injury on his life.

He said, “I was unable to carry out normal daily tasks such as tying my shoelaces. “My right hand is my dominant hand, and I find it extremely difficult to write with that hand now.

“I am now self-conscious when I go outside. “My family has also been affected by the injury, as I am unable to do normal things I used to be able to do before. “As a result of the injury, I feel my job prospects have been affected, both now and in the future.”

An investigation by the Health and Safety Executive (HSE) has revealed significant safety failings at Film & Foil Solutions Ltd. The company was found to have inadequately protected its employees due to several critical oversights.

The HSE investigation specifically identified that Film & Foil Solutions Ltd:

• Failed to implement suitable guarding on machinery used in production, directly compromising employee safety.
• Did not conduct a suitable and sufficient risk assessment, which led to the absence of appropriate guarding on machinery.
• Lacked an adequate safe system of work, increasing the risk of incidents.
• Provided inconsistent and insufficient information, instruction, and training for employees operating the machinery.

On May 15, 2025, Film & Foil Solutions Ltd was fined £20,000 and ordered to pay £2,932 in costs at Sefton Magistrates' Court after pleading guilty to breaching Regulation 11(1) of The Provision and Use of Work Equipment Regulations 1998.

HSE inspector Sam Eves said, “This incident could so easily have been avoided had the company taken simple steps to guard dangerous parts of machinery and implement safe working practices.

“Companies and individuals should be aware that HSE will not hesitate to take appropriate enforcement action against those that fall below the required standards.”

This HSE prosecution was brought by HSE Enforcement Lawyer Matthew Reynolds and supported by Paralegal Officer Imogen Isaac.