Two companies were prosecuted by the Health and Safety Executive (HSE) following an investigation into the incident in Barugh Green.
Barnsley Magistrates' Court heard that the employee got caught on a computer controlled conveyer system for moving heavy steel beams, after peering into an outlet point to check a line of work.
His clothing snagged on the machine and he was forced though an opening just 125mm wide on the machine head, approximately the size of a CD case, suffering injuries that have caused lasting physical and psychological damage.
His trauma included rupturing his stomach and bowel, breaking his back in two places, shattering his pelvis, and fracturing both hips, his right arm and several ribs.
The HSE investigation into the incident, which happened on 19 December 2008, found there was no guarding in place to protect the worker from dangerous moving parts - a serious safety failing for both his employer and the machine supplier.
The court was told that both parties were responsible for ensuring sufficient guarding was in place. The machine ultimately belonged to the company after it was bought from new, but the machine supplier installed and signed-off the equipment as being fit and ready for use.
HSE investigators also established that the employee was inexperienced in operating the machinery after being moved from a different line at the factory because of a lull in his regular workload. However, it was the lack of guarding that was deemed the decisive factor.
The engineering firm pleaded guilty to breaching Section 2(1) of the Health and Safety at Work etc Act 1974 in relation to the incident. The machine supplier pleaded guilty to breaching Section 6(1)(a) of the same legislation. Magistrates have remitted the case to Sheffield Crown Court for sentencing.
After the hearing, HSE inspector Chris Chambers said:
"It almost defies belief that a body could contort in such a way to fit through the opening it did, and it's even more astonishing that this man survived to tell the tale.
"Granted he will never fully recover from the trauma he endured, but he could easily have been killed, and I could easily be commenting on another life needlessly lost because of basic safety failings.
"The engineering firm have at least had the good grace to stand by their employee and provide continued support, but both they and the machine supplier ultimately failed to protect the young worker when it mattered most.
"Had appropriate guarding been in place the incident would never have occurred in the first place. I hope today's prosecution serves as a firm reminder to all involved in manufacturing and processing of the need to properly restrict exposure and access to dangerous moving parts."
After the case, the employee said:
"What matters most is that the industry learns from my experience. My life has changed forever and no matter how well I recover from my physical injuries I will still have the psychological impact of the accident hanging over me.
"I hope my case highlights the dangers posed by not following health and safety regulations. It still won't be able to put my life back to how it was before the accident but at least then it might prevent others from suffering in the future.
"Too many people are needlessly killed and injured in accidents at work. If hearing my story makes them think twice about safety and about the daily risks they face in the work place, then I'll be happy. Eliminating risk is now a big part of my life as I train to become a site supervisor. I know more than most why that is so important - and I really hope that message gets through.
"I would like to thank the doctors, my family, friends, the HSE and my solicitors for their help and support over this difficult time. I now hope to put the worst behind me and begin to move on with my life."
Also reported by Construction Enquirer.