Key Responsibilities and Required Skills for Unit Operations Technician

🎯 Role Definition

The Unit Operations Technician is responsible for the safe, efficient operation and maintenance of process unit equipment (pumps, valves, heat exchangers, distillation columns, reactors, filtration systems, sterilizers, CIP/SIP systems and associated utilities), ensuring product quality, regulatory compliance (GMP/cGMP/HACCP as applicable), and continuous production throughput. This role requires hands-on mechanical and process troubleshooting, adherence to safety and environmental protocols, accurate process documentation, and close collaboration with production, maintenance, quality, and engineering teams to drive operational excellence.

📈 Career Progression

Typical Career Path

Entry Point From:

Production Operator / Process Operator
Maintenance Technician or Millwright
Chemical Plant Operator / Lab Technician

Advancement To:

Senior Unit Operations Technician / Lead Operator
Shift Supervisor or Operations Team Lead
Process or Manufacturing Engineer

Lateral Moves:

Quality Technician / Quality Assurance Specialist
Control Room Operator / SCADA Technician
Maintenance Planner or Reliability Technician

Core Responsibilities

Primary Functions

Operate and control unit operations equipment (reactors, distillation towers, evaporators, centrifuges, filters, membrane systems, heat exchangers, pumps, compressors and valves) according to standard operating procedures (SOPs) and batch records to meet production schedules and quality specifications.
Monitor process parameters (temperature, pressure, flow, level, pH, conductivity, and concentration) continuously using distributed control systems (DCS) or SCADA and make timely adjustments to maintain stable and efficient operation.
Execute routine startup, shutdown and normal/abnormal operating procedures for process units and coordinated changeovers to minimize downtime and prevent product loss.
Troubleshoot mechanical, process and instrumentation issues on unit operations equipment, isolate root causes using process data and implement corrective actions or escalate to maintenance/engineering when required.
Perform preventive maintenance tasks and minor mechanical repairs (pump seal changes, valve packing, filter changes, belt and bearing replacements) in accordance with maintenance schedules and CMMS work orders.
Lead and participate in cleaning, CIP (clean-in-place) and SIP (sterilize-in-place) procedures ensuring validation and documentation are completed to meet sanitary and regulatory standards.
Conduct in-process sampling and testing per QA/QC procedures, document sample results in batch records and promptly notify Quality or Supervisors of out-of-specification (OOS) results.
Apply and enforce safety and environmental compliance measures, including lockout-tagout (LOTO), confined space entry, hot work permits, chemical handling protocols, and PPE adherence to prevent incidents and exposures.
Execute emergency response actions for spills, leaks, and equipment failures, including containment, notification, and support for incident investigations and corrective/preventive actions.
Maintain accurate process and equipment records, complete batch documentation and electronic logbooks in line with GMP, cGMP and regulatory requirements, ensuring traceability and audit readiness.
Collaborate with process engineers to support unit optimization projects, including process debottlenecking, throughput improvements and energy efficiency initiatives, by providing operational insight and performing pilot tests.
Perform routine calibration verification and basic troubleshooting of field instrumentation (temperature probes, pressure transmitters, flow meters, level sensors) and coordinate calibration services with instrumentation/engineering teams.
Operate and monitor PLC logic and HMI screens for local unit controls, follow change control procedures for parameter changes, and assist automation teams with validating control system updates.
Execute mechanical transfers of liquids and slurries using pumps and transfer lines, ensure correct line-up with valves and piping systems and verify containment to avoid cross-contamination and product loss.
Support changeover, cleaning and sanitation of product-contact equipment to prevent cross-contamination in multi-product facilities and ensure compliance with product segregation and allergen controls.
Supervise contractors and maintenance personnel during mechanical interventions on unit equipment, verify proper isolation and permit compliance, and validate returned-to-service conditions prior to restart.
Participate in continuous improvement and lean manufacturing activities, identify opportunities to reduce waste, improve yield and increase reliability, and lead small-scale kaizen events for unit improvements.
Conduct routine inspections and housekeeping of the unit area to ensure OSHA, environmental and site housekeeping standards are met and maintain clear access to safety equipment and egress routes.
Train and mentor junior operators on safe operation, SOPs, emergency procedures and basic troubleshooting techniques to build team capability and ensure consistent unit performance.
Prepare and present shift handover reports, communicate operational status, open action items and outstanding maintenance needs clearly to incoming shifts and relevant stakeholders.
Implement and document containment and segregation procedures for hazardous materials, follow MSDS safety instructions, and support hazardous waste disposal procedures in accordance with environmental regulations.
Participate in process validation, qualification activities (IQ/OQ/PQ) and support regulatory inspections by providing accurate operational records and technical explanations of unit procedures.

Secondary Functions

Support continuous improvement data collection by recording key process metrics, downtime reasons and efficiency trends to enable data-driven decision making.
Assist quality and regulatory teams with documentation requests, batch record review and root cause investigations for deviations and nonconformances.
Contribute to the development and revision of SOPs, work instructions and training materials based on observed best practices and operational feedback.
Coordinate cross-functional troubleshooting calls between production, maintenance, engineering and quality to expedite resolution of complex process issues.
Participate in scheduled training refreshers (safety, GMP, HACCP, LOTO) and site-wide initiatives to raise compliance and operational standards.

Required Skills & Competencies

Hard Skills (Technical)

Proven hands-on experience operating process unit equipment: pumps, valves, heat exchangers, distillation and filtration systems, centrifuges, reactors and compressors.
Familiarity with process control systems (DCS, PLC, SCADA) and ability to interpret HMI screens, alarms, historian trends and basic ladder logic concepts.
Strong troubleshooting skills for mechanical, electrical and process issues — able to use root cause analysis methods (5 Whys, Fishbone) and implement corrective actions.
Experience with CIP/SIP protocols, sterilization processes, and sanitary cleaning in food, beverage, pharmaceutical or biotech environments.
Knowledge of GMP/cGMP, HACCP, ISO and other regulatory or quality systems relevant to manufacturing.
Competence in executing lockout-tagout (LOTO), confined space entry, hot work permits and other safety procedures.
Ability to read and follow P&IDs, process flow diagrams (PFDs), piping and instrumentation diagrams and technical manuals.
Experience with preventive maintenance programs and computerized maintenance management systems (CMMS) such as SAP, Maximo or similar.
Basic instrumentation skills: verifying/calibrating temperature probes, pressure transmitters, flow meters, level sensors and gas detectors.
Familiarity with hazardous materials handling, HAZMAT/HAZWOPER principles and appropriate PPE selection.
Experience with batch record documentation, electronic batch records, and data integrity practices.
Comfortable performing minor mechanical repairs and using hand tools, power tools and lifting devices safely.
Knowledge of process safety fundamentals (PSM, HAZOP exposure, process risk assessments) and participation in safety reviews.

Soft Skills

Strong verbal and written communication skills for shift handovers, cross-functional coordination and clear documentation.
Attention to detail and disciplined adherence to SOPs, checklists and quality processes.
Critical thinking and analytical mindset to interpret process data, spot trends and escalate issues appropriately.
Team player with ability to mentor junior staff and work collaboratively with maintenance and engineering teams.
Time management and prioritization skills to balance routine operations, emergency responses and maintenance activities.
Adaptability and calm decision-making under pressure during upset conditions or emergencies.
Continuous improvement mindset with curiosity to identify root causes and propose sustainable fixes.
Strong situational awareness and personal accountability for workplace safety and regulatory compliance.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED; vocational or technical certificate in process technology, mechanical or electrical trade preferred.

Preferred Education:

Associate degree in Process Technology, Chemical Engineering Technology, Mechanical Technology, Industrial Maintenance or related field.
Certifications such as OSHA 10/30, HAZWOPER, NFPA awareness, or relevant trade certifications add value.

Relevant Fields of Study:

Process Technology / Chemical Process Technology
Mechanical or Electrical Trades (Millwright, Industrial Electrician)
Industrial Maintenance / Instrumentation and Controls
Chemical Engineering Technology

Experience Requirements

Typical Experience Range: 1–5 years of hands-on experience in manufacturing, process operations, or unit operations within chemical, pharmaceutical, biotech, food & beverage or related industries.

Preferred: 3+ years operating and maintaining process unit equipment with demonstrated experience in CIP/SIP, GMP/cGMP environments, and working knowledge of DCS/PLC/SCADA systems.

Certifications and licenses (forklift, confined space, first aid/CPR) and documented safety training are highly desirable.