"We have investigated a number of possible causes for the misfiring of our white hand held flare and have now been able to simulate the situation to give the same effect, " Lucas told BB.

"And the most likely cause is under-volume as a result of under fill."

The process area which led to the under fill could have affected a small number of red hand flares, he added, but extensive tests on those flares showed red hand flares burn in different ways and there was no indication that red hand flares could deflagrate if made with less material than intended.

Red and white hand flares contain different materials that burn in different ways to give their colours, said Lucas, and white flares burn more energetically than red because of these differences.

Red flares - even if underfilled - would not react in the same way as the white hand flare, he insisted. "There is absolutely no danger of this happening on any PW red hand flare, " he told BB.

The product recall of Pains Wessex white hand flares is running at 20%, which is apparently above the anticipated return rate.

"We're still pushing heavily in lots of countries, " said Lucas.

"Some of those are only just getting out on the water now."

The media has helped Pains Wessex a lot and feedback from the UK market is that the recall is widely known and understood, but PW is still advertising in French, Dutch and Belgian magazines to emphasise the recall.

The demonstrator injured in the misfiring back in April was still in intensive care as we went to press, although it's hoped he will be moved to a normal ward in the near future. He remains on morphine and is still undergoing surgery.

He was visited by his lawyer recently?