A Chemical Operator is a professional who plays a crucial role in the manufacturing and production processes of various chemical products. They are responsible for operating and monitoring equipment, maintaining safety standards, and ensuring the efficient and effective execution of chemical processes. In this blog post, we describe the primary responsibilities and the most in-demand hard and soft skills for Chemical Operators.

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Main Responsibilities of a Chemical Operator

The following list describes the typical responsibilities of a Chemical Operator:

Adhere to

• Adhere to any and all Palmer safety requirements and waste procedures.

• Adhere to standard safety procedures during equipment lockout/tagout.

Adjust

Adjust controls to regulate variables as per instructions.

Alert

Alert the team leader to safety, quality, and equipment problems.

Analyze

Analyze charts and logs to identify potential or actual problems.

Apply

Apply documented processes to safely operate and troubleshoot chemical processes.

Assist in

• Assist in development and continuous improvements of Adhesive Manufacturing SOP's.

• Assist in development and continuous improvements of our 6'S program.

• Assist in packaging product for shipment and in loading / unloading product or raw materials.

• Assist in the development and improvement of manufacturing processes.

• Assist in training of new Chemical Operators.

Attend

• Attend classes as designated to facilitate above knowledge and to maintain required updates.

• Attend training courses as required.

Audit

Audit other team members in safety and quality procedures.

Calculate

Calculate batch yields and responds appropriately.

Charge

Charge chemicals, cook batches using heating and / or cooling.

Clean

Clean drums for shipment to drum disposal facilities.

Collaborate with

• Collaborate with maintenance teams for equipment repairs and upgrades.

• Collaborate with team members to optimize production efficiency.

Communicate

Communicate effectively with supervisors, colleagues, and other stakeholders.

Complete

Complete all production and / or shift documentation in a timely manner & with accuracy.

Conduct

• Conduct accurate cycle counts in the solutions area.

• Conduct DCS operation to manipulate equipment controlled by the DCS.

• Conduct in process Quality Control testing.

• Conduct quality control tests to ensure product consistency and meet specifications.

• Conduct routine inspections of equipment and systems.

Contribute to

Contribute to the completion of routine tasks.

Control

Control and adjust process variables such as temperature, pressure, and flow rate.

Develop

• Develop into a process expert and translate knowledge to others as needed.

• Develop productivity output efficiencies by determining prioritization of Work Orders.

• Develop solutions to routine problems following established Pfizer policies and procedures.

Dispense

Dispense and charge materials into process vessels.

Employ

Employ best practices in inventory management by using FIFO and stock counts.

Ensure

• Ensure all equipment is put back into proper locations at the end of each day.

• Ensure compliance with safety and environmental regulations.

• Ensure that the production of reagent batches are completed in a timely and efficient manner.

Execute

Execute batch instructions.

Filter

Filter and drum out finished product.

Follow

• Follow all relevant department and site safety practices and policies.

• Follow all written manufacturing formulations operating instructions.

• Follow Good Manufacturing Practices (cGMP) and pharmaceutical operating techniques.

• Follow gowning requirements.

• Follow protocols for handling hazardous materials and chemicals.

• Follow specific, detailed instructions.

• Follow standard operating procedures (SOPs) for chemical production.

• Follow the direction of the shift coordinator in a professional and cordial manner.

• Follow waste handing guidelines as specified in plant procedures.

• Follow work instructions (WI) and Product Quality Control Plans (PQCP).

Gather

Gather and record operating information and data.

Handle

• Handle and organize hazardous and non-hazardous waste.

• Handle solid chemicals as chemical intermediates, products and waste.

Help

Help to monitor pollution control equipment to assure compliance with air and water discharges.

Identify

• Identify and report any safety hazards or concerns.

• Identify opportunities for process optimization and waste reduction.

• Identify system problems to stabilize plant to normal conditions.

Implement

Implement and adhere to good manufacturing practices (GMPs).

Inspect

Inspect all containers prior to filling for cleanliness and integrity.

Keep

• Keep accurate records of production data and process parameters.

• Keep work area safe and clean.

Label

Label hazardous waste containers as appropriate.

Learn

Learn reactor setup, thoroughly follow batch tickets and complete paperwork.

Maintain

• Maintain accurate records.

• Maintain a clean and organized work area.

• Maintain a clean and organized work area and strictly adheres to all plant safety policies.

• Maintain a high level of professionalism and work ethics.

• Maintain and clean tools or other aids and store in the proper location.

• Maintain appropriate batch and shift paper work.

• Maintain a safe, productive workplace by practicing safe handling procedures.

• Maintain a safe working environment.

• Maintain lot and material traceability.

• Maintain neat, thorough and correct completion of all batch related documentation.

• Maintain strong focus on Safety, Health and Environmental (SHE) principles.

• Maintain the production area(s) in a clean and orderly condition.

• Maintain work area in a neat and orderly fashion.

Make

Make recommendations for changes / improvements to ISO-9000 work procedures as needed.

Measure

• Measure all raw, in process, and finished materials in an accurate manner.

• Measure and mix chemicals according to specific formulations.

Minimize

Minimize waste generation.

Monitor

• Monitor and control waste disposal procedures.

• Monitor and maintain inventory levels of raw materials and chemicals.

• Monitor energy usage and optimize energy efficiency.

Move

• Move about freely in a laboratory setting.

• Move all scrap, empty containers, and production waste to the proper disposal area.

• Move raw materials and / or finished goods using forklift upon receiving company certification.

Offer

Offer suggestions to improve Standard Operating Procedures (SOP s).

Operate

• Operate all milling and lifting equipment per SOP and work instructions.

• Operate all types of Forklifts and other related motorized vehicles in a safe and proficient manner.

• Operate and monitor chemical processing equipment.

• Operate chemical process systems and related equipment.

• Operate fork trucks and drive yard tractor to manipulate box and tank trailers about the plant site.

• Operate industrial mixing and powerlifting equipment by controlling mixing instructions.

• Operate mobile equipment including manlifts, fork trucks, yard-dog and trackmobile.

• Operate, monitor and control plant systems.

• Operate process equipment, such as filter presses, pumps and agitators.

Oversee

Oversee and assist weighing, mixing and testing of products to meet production demands.

Participate in

• Participate in continuous improvement initiatives.

• Participate in problem resolution as it relates to quality issues with batches.

• Participate in safety training programs and promote a culture of safety.

• Participate / Lead various site teams.

Perform

• Perform all MMRP and CMMS transactions.

• Perform all tasks in a safe manner and following plant safety policies and procedures.

• Perform all tasks that are required to operate the chemical processing unit at the facility.

• Perform cleaning of chemical processing equipment's and facilities.

• Perform duties required in operating a variety of equipment used to manufacture Heparin Active.

• Perform inspections and checklists for pollution control devices.

• Perform laboratory analysis of products.

• Perform loading and unloading of railcars, tank trucks and totes.

• Perform minor maintenance activities on production equipment as directed by the Operations Manager.

• Perform minor maintenance on process and support equipment.

• Perform minor service maintenance on equipment as defined by the Operation Manager.

• Perform ratio analysis to adjust batch concentrations.

• Perform repetitive hand and arm motions.

• Perform routine cleaning of process equipment and work areas.

• Perform routine equipment maintenance and calibration.

• Perform set up procedures to prepare systems for operation.

• Perform shipping, packaging and receiving activities as needed.

• Perform shipping, packaging, and receiving activities as needed.

• Perform transaction in ERP system and perform various other duties on the computer.

• Perform twisting, bending, stooping motions.

• Perform yard and building cleanup as needed.

Pick

Pick and prepare shipments of various chemicals, including Hazardous Materials.

Prepare

• Prepare equipment for maintenance work.

• Prepare equipment for maintenance work by isolating, clearing and locking out.

• Prepare mixing vessels, necessary pumps and hoses for unloading.

• Prepare Work Orders as required to maintain the operating units.

Produce

Produce sulfuric acid in multiple concentrations.

Provide

• Provide immediate containment, reporting and clean-up / recovery of spilled material or leaks.

• Provide operator help to other plant 98 employees as appropriate.

• Provide support during plant startups and shutdowns.

• Provide training as necessary to less experienced operators.

Raise

Raise after completing a satisfactory 100 days.

Reach

Reach with hands and arms.

Receive

Receive, sample, label and ship chemicals and products.

Recognize

Recognize abnormalities in a High Hazard work area and promptly initiate action.

Record

• Record all inventory transactions in location and weighed amount.

• Record weights neatly and accurately.

Reduce

Reduce quality errors by investigating and determining sources of errors.

Refer

Refer to Training Matrix for comprehensive list).

Report

• Report any extraordinary conditions to supervision which could compromise product quality.

• Report any process upset, spill, injury, chemical release, security event, etc..

Respond to

• Respond promptly to emergencies or abnormal process conditions.

• Respond to process alarms.

Set-up

Set-up, operate, and monitor reactors.

Start

Start up and shut down (normal and emergency) plant systems and components.

Stay updated with

Stay updated with industry trends, technologies, and best practices.

Take

Take samples of raw materials and process streams.

Train

• Train and mentor new operators.

• Train new operators in the area, reinforcing safety and environmental principles.

Troubleshoot

• Troubleshoot abnormal situations and take corrective action.

• Troubleshoot and resolve equipment malfunctions or process deviations.

• Troubleshoot equipment to restore to normal operation.

• Troubleshoot equipment to restore to operation.

Understand

Understand and follow safe handling procedures for all chemicals.

Use

• Use all production equipment and hand tools in a safe and proper manner.

• Use company computer to enter records and documents.

• Use company computer to enter records, and documents.

• Use lift vehicles, power jacks, and drum dollies.

• Use of eye protection is required.

• Use of hearing and eye protection is required.

• Use of hearing, hand, head, feet, eye and repertory protection is required.

• Use of required Safety equipment.

• Use protective equipment (PPE) as needed to prevent exposure to dangerous chemicals.

Weigh

Weigh and load raw material into vessels.

Work

• Work cooperatively as an active member of own and cross-functional teams.

• Work daily to insure areas of responsibility are meeting housekeeping standards to avoid hazards.

• Work to ensure the operability of equipment is maintained to high standards.

Most In-demand Hard Skills

The following list describes the most required technical skills of a Chemical Operator:

1. Knowledge of chemical processes and reactions.

2. Proficiency in operating process control systems.

3. Ability to read and interpret technical documents and schematics.

4. Strong understanding of safety protocols and hazardous materials handling.

5. Familiarity with operating and troubleshooting various types of equipment.

6. Competence in using analytical instruments and laboratory techniques.

7. Understanding of quality control and assurance principles.

8. Knowledge of environmental regulations and waste management practices.

9. Ability to perform basic mathematical calculations and unit conversions.

10. Proficiency in computer skills and data analysis software.

11. Familiarity with process simulation software.

12. Understanding of instrumentation and control systems.

13. Knowledge of mechanical systems and maintenance procedures.

14. Proficiency in conducting root cause analysis and problem-solving.

15. Ability to operate forklifts and other material handling equipment.

16. Understanding of electrical systems and wiring diagrams.

17. Knowledge of process automation and control strategies.

18. Proficiency in using standard laboratory equipment.

19. Understanding of standard operating procedures (SOPs) and protocols.

20. Knowledge of safety regulations and emergency response procedures.

Most In-demand Soft Skills

The following list describes the most required soft skills of a Chemical Operator:

1. Strong attention to detail and accuracy.

2. Excellent communication skills, both verbal and written.

3. Ability to work effectively in a team environment.

4. Strong problem-solving and critical-thinking abilities.

5. Adaptability and flexibility in a dynamic work environment.

6. Excellent time management and organizational skills.

7. Ability to follow instructions and adhere to procedures.

8. Strong work ethic and commitment to quality.

9. Effective decision-making skills.

10. Ability to work under pressure and meet deadlines.

Conclusion

The role of a Chemical Operator involves a diverse set of responsibilities that require a combination of technical and soft skills. By possessing the necessary hard skills and demonstrating the essential soft skills, Chemical Operators contribute to the safe and efficient production of chemical products. As the demand for chemical manufacturing continues to grow, individuals with a strong skill set and a passion for the industry will find rewarding opportunities as Chemical Operators.