HSE Cracks Down on Bakery Safety After £120,000 Fine
The Health and Safety Executive (HSE) has significantly ramped up its inspection programme across large bakeries in Great Britain, a move prompted by a recent £120,000 fine issued to a food manufacturer for serious breaches of health and safety regulations. The case highlights ongoing concerns regarding exposure to hazardous substances under the Control of Substances Hazardous to Health (COSHH) Regulations 2002 and inadequate manual handling practices within the food manufacturing sector.
Puratos Limited, a Buckingham-based food manufacturer, pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc. Act 1974. Milton Keynes Magistrates' Court heard how workers were at risk of developing occupational asthma due to high levels of inhalable flour dust and musculoskeletal injuries from manual handling of heavy 25kg sacks. The court imposed a fine of £120,000 and ordered the company to pay costs of £6,270 on July 17, 2026.
HSE inspectors identified several unsafe practices during an inspection on December 3, 2024, including dust escaping from machinery, the use of compressed air for blow-down cleaning, and dry sweeping – all of which contribute to increased airborne dust. A subsequent workplace dust monitoring report on December 18, 2024, confirmed that employees were exposed to inhalable dust concentrations exceeding the Workplace Exposure Limits (WELs) set by the HSE. This was not the first time Puratos Limited had been subject to enforcement action; a 2021 inspection had also raised concerns about dust exposure and manual handling risks.
The Pervasive Risk of Flour Dust and Manual Handling
HSE Inspector Emma Page emphasised the preventable nature of such incidents, stating, "Too many workers in bakeries are suffering from unnecessary exposure to dusty ingredients, including flour." Flour dust is a well-known respiratory sensitiser and a leading cause of occupational asthma. Its dangers have been documented for centuries, with Bernardino Ramazzini noting respiratory diseases among millers and bakers as early as 1700.
The current inspection programme, initiated in January 2026, specifically targets large bakeries to ensure employers are adequately protecting workers from dusty ingredients. Alongside respiratory hazards, manual handling continues to be a significant concern. The repeated lifting of heavy loads, such as 25kg ingredient sacks, can lead to debilitating musculoskeletal disorders, and employers are required to avoid such risks where reasonably practicable.
The HSE's focus on the food sector extends beyond bakeries. The agency has issued renewed calls for vigilance and strict COSHH compliance across the broader food manufacturing and catering industries. While often associated with biological hazards, food environments also involve numerous chemicals, cleaning agents, and naturally occurring substances that pose health risks if not properly managed. Failures in controlling exposure to hazardous substances contribute significantly to work-related ill health, with respiratory problems being a substantial occupational health issue.
Understanding and Complying with COSHH and RIDDOR
The Control of Substances Hazardous to Health (COSHH) Regulations 2002 mandate employers to control exposure to hazardous substances to prevent ill health. This includes a wide array of substances such as chemicals, fumes, dusts, vapours, mists, gases, and biological agents. Employers are legally required to conduct suitable and sufficient COSHH risk assessments, which involve identifying hazardous substances, evaluating health risks, and implementing appropriate control measures. These assessments should be ongoing, regularly reviewed, and updated.
Related training: If you are looking to qualify as a trainer in this area, see online health and safety training or explore COSHH assessor training for nationally recognised UK and Ireland qualifications.
The hierarchy of control measures, from elimination and substitution to engineering controls, administrative controls, and finally, personal protective equipment (PPE), should be followed. Relying solely on PPE without considering other controls is not compliant with COSHH.
In parallel, the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR) 2013 place legal duties on employers and self-employed individuals to report certain work-related incidents to the HSE. Reportable incidents include:
- Deaths and specified major injuries to workers (reported without delay).
- Injuries causing more than seven days' incapacitation (reported within 15 days).
- Injuries to non-workers requiring hospital treatment.
- Diagnosed occupational diseases.
- Certain dangerous occurrences (near misses).
For the period 2023/24, provisional figures indicate 138 worker fatalities in work-related accidents across Great Britain, an increase of two from the previous year. Additionally, 61,663 non-fatal injuries to employees were reported under RIDDOR. The most common non-fatal injuries reported were slips, trips, and falls (31%), and handling, lifting, or carrying incidents (17%).
The Food Standards Agency (FSA), in partnership with Food Standards Scotland (FSS), also plays a crucial role in ensuring food safety and consumer protection across the UK. They regularly issue guidance on various aspects of food safety, including novel foods and allergen information. In Ireland, the Food Safety Authority of Ireland (FSAI) performs a similar function, working with Environmental Health Officers to enforce food safety legislation and protect public health.
Maintaining high standards in health and safety, including comprehensive COSHH assessments and accurate RIDDOR reporting, is crucial for all businesses. For expert training and consultancy in these areas, consider Abertay Training at https://www.abertaytraining.co.uk.