Fish processing firm Pelagia Shetland fined £451,000 after worker became entangled in machine

A fish processing company has been fined £451,000 after a worker in Shetland became entangled in a palletiser machine.

Forklift supervisor Curtis New suffered multiple fractures and two collapsed lungs in the incident at Pelagia Shetland Limited’s plant in Lerwick on October 10, 2024.

The 41-year-old had been called to clear a blockage and having struggled to open an interlocking safety gate, removed a panel and entered the machine area.

While walking towards the blockage, he triggered a sensor which restarted the machine and he was repeatedly struck by its pushers before a colleague hit the emergency stop button.

Mr New was airlifted to Aberdeen Royal Infirmary following the incident, where he spent ten days in intensive care and a further ten days in a high dependency unit.

He suffered eight fractured ribs, a fractured pelvis in five places, a fractured clavicle and scapula, and two collapsed lungs. He was later transferred to Gilbert Bain Hospital in Lerwick for rehabilitation, and has since said he does not wish to return to his role.

Following an investigation by the Health and Safety Executive, inspectors found that perimeter safety fencing around the machine, designed to isolate its power supply whenever the interlocking safety gate was opened, had become insecure after a panel was damaged.

The gate had been struck by a forklift truck in early 2024, damaging its locking mechanism and making it difficult to open. Rather than use the gate, two senior staff, including Mr New, had taken to removing the loose panel to clear frequent blockages in the machine, without isolating the power first.

The incident involving Mr New was referred to HSE on the same day by the fish processing firm, and following an investigation, Pelahia Shetland reinstated its perimeter fencing so that the machine can only be accessed via the gate. Safety practices were also updated to ensure staff do not bypass safety barriers, or face disciplinary action.

Pelagia Shetland pleaded guilty to health and safety failings at Lerwick Sheriff Court on Wednesday and was fined £420,000. The firm must also pay a victim surcharge of £31,500.

HSE inspector Matty Spiers said: “This was a wholly avoidable incident that left a man with life-threatening injuries, and it happened because a basic, well-understood safety control was allowed to fail.

“Interlocking guards exist for one reason: to stop people reaching dangerous machinery while it’s still live. When that gate was damaged, it should have been repaired properly and its integrity restored immediately, not left in a state where a determined employee could simply lift out a panel and walk into a hazardous area.

“Curtis New is fortunate to be alive. He suffered catastrophic injuries carrying out a task that should never have been possible without the machine being isolated first.

“Employers have a legal duty to make sure guarding and interlock systems are properly maintained, and that any weakness is identified and corrected without delay. This isn’t a bureaucratic box-ticking exercise, it’s what stands between a workforce and a serious, life-changing injury.”

Pelagia has been contacted for comment.