The reality of machinery injuries: what every worker should know

Every year, thousands of Australian workers are injured by machinery.

In 2023–24, more than 18,300 serious workers’ compensation claims were lodged by machinery operators and drivers. On average, each workplace injury meant around nine weeks away from work. That’s nine weeks of lost income, disruption and uncertainty for workers and their families.

This industry also records the highest rate of workplace fatalities in Australia. Machinery operators and drivers account for around 32 per cent of all worker deaths, with a fatality rate of about 6.7 deaths per 100,000 workers.

These numbers are confronting. But statistics only tell part of the story.

I’ve represented clients who have suffered life-changing injuries because of a single moment at work. In almost every case, the injury wasn’t caused by reckless behaviour. It was caused by something small that should have been fixed.

A safety guard that wasn’t replaced, a machine that wasn’t properly locked out and isolated, or a safety check that was skipped because someone was in a hurry. When you see the aftermath of these incidents, you realise how thin the line is between a normal day at work and a life-altering work injury.

Why workplace machinery injuries are so severe

Machinery is dangerous because it combines immense power with unforgiving precision.

These machines are designed to cut, crush, lift and move heavy loads. When something goes wrong, that same force can cause catastrophic physical injuries in an instant.

Safety controls exist to reduce this risk. Guards and emergency stops are there for a reason. Yet in high-pressure environments, they are often removed or bypassed to save time.

Maintenance adds another layer of risk. Servicing machinery while it’s still energised is one of the most common causes of serious injuries in this industry. A sudden start-up can turn a routine task into a life-threatening emergency.

Noise, poor visibility, and fatigue increase the risk even further. On busy worksites, workers can miss warning signs until it’s too late.

The harsh truth is this: most machinery injuries are preventable. Prevention depends on a workplace culture that values safety as highly as productivity.

What employers and workers can do to prevent work injuries

Workplace safety begins with leadership.

Employers set the tone for the entire workplace. When they invest in proper training and consistently enforce procedures, they send a clear message that safety matters.

Leading by example is critical. When managers take shortcuts, workers notice. When hazards are ignored, it tells everyone that safety is optional. It should never be optional. Every missed detail can have devastating consequences, and leadership plays a key role in preventing those moments.

Workers also play an important role. If something feels unsafe, speak up. Report hazards and near misses, even if they seem minor. These isn’t a new ideology; they’re proven practices that save lives and can make all the difference in your workplace.

The reality behind a routine task gone wrong

For one of my clients, a normal day on the production line became the moment everything changed.

He was working at a meat processing plant, helping keep the line moving by removing sheep hides that the primary hide‑pulling machine had missed. It was busy, the kind of frantic pace where workers had to move fast just to keep up. When the machinery failed to catch several carcasses in a row, staff quickly switched to the back‑up hide puller, attaching chains while the machine kept running. According to him, this was common practice. It shouldn’t have been.

In the middle of all this, a chain he had wrapped around his wrist became entangled in the moving machinery. Before he had a chance to react, the back‑up hide puller dragged him in. His left hand and wrist were severed instantly.

An ordinary shift turned into a life-altering trauma.

We supported him through every step of his workers’ compensation claim, helping him get the compensation he deserved. But no amount of compensation could restore what he lost.

This is the reality behind the statistics. Every number represents a real person whose life, work and family have been affected.

Getting legal help after a work injury

If you've been injured at work, you don’t have to navigate the workers’ compensation claim process alone. A work injury claim can help cover lost income, medical treatment, rehabilitation, and ongoing support after a serious machinery injury. Our dedicated workers' compensation lawyers can guide you through your legal options and are here to help you get back on track, so you can focus on getting better.

You can use our free claim check tool to find out if you are eligible for a worker's compensation claim. You can also send us a message or call us on 1800 111 222.