Huws Gray Fined £2.2 Million After Tragic Conveyor Belt Fatality

Building merchant Huws Gray has been fined £2.2 million following the tragic death of a worker, Paul Coulson, who was crushed by a three-tonne pallet of timber at their Herringswell Sawmills site in Suffolk in May 2024. The incident occurred when a colleague unknowingly started a conveyor belt while Mr Coulson was inside its framework, leading to fatal crush injuries.

Key Takeaways

Huws Gray pleaded guilty to breaching the Health and Safety at Work Act.
The company was fined £2.2 million and ordered to pay £9,929 in costs.
The incident highlights failures in safeguarding machinery and preventing access to dangerous areas.

The Fatal Incident

The tragic event unfolded on May 22, 2024, when 56-year-old labourer Paul Coulson was tasked with removing plastic packaging from timber pallets before they entered the mill’s processing machinery. Mr Coulson climbed inside the conveyor’s framework to access some of the packaging. However, another operative, unable to see him, started the conveyor. The pallet of timber moved forward, colliding with Mr Coulson. The operative attempted to reverse the pallet, but this resulted in a second collision, causing fatal crush injuries.

Investigation and Findings

An investigation by the Health and Safety Executive (HSE) revealed that Huws Gray had previously identified employees accessing the danger zone within the conveyor and had placed signage instructing them not to. Despite this, CCTV analysis showed that between April 14 and May 23, 2024, operatives entered the conveyor framework on 19 separate occasions. While warning stickers were placed on the machinery, no further action was taken to prevent access until after the tragedy.

Sentencing and Company Response

At Chelmsford Magistrates’ Court on March 26, 2026, Huws Gray Limited pleaded guilty to breaching the Health and Safety at Work etc Act 1974. The company was fined £2.2 million and ordered to pay full costs. In a statement, Huws Gray acknowledged the judgment, expressed deep regret, and stated that their thoughts remain with Mr Coulson’s family. They emphasised that additional safety measures have been swiftly implemented to prevent future occurrences.

HSE Statement and Recommendations

HSE inspector Joanne Williams described the incident as a “staggering failure” that cost a man his life. She highlighted that the company chose to control a serious risk through instruction alone, rather than implementing proper safeguarding measures. The HSE stressed that all companies must follow the hierarchy of control for guarding dangerous machinery. Following the incident, Huws Gray introduced physical guards on the conveyor, procedural changes to ensure pallets are unwrapped before processing, and increased CCTV coverage.