Chemical plant process workers operate and monitor machinery used in the manufacture of industrial and domestic products such as:

• pharmaceuticals
• petrochemicals
• paints
• plastics
• fertilisers
• detergents
• cosmetics and toiletries.

The job varies depending on the type of equipment workers use but can include:

• setting up and preparing the machinery ready for production
• measuring, weighing, mixing and loading raw materials into the machines, including blenders, screeners, evaporators and reaction vessels
• monitoring meter and instrument readings, making necessary adjustments
• taking product samples and recording the test data for quality purposes
• packing and loading finished products into barrels, tanks or other containers ready for dispatch
• closing down and cleaning plant and machinery, and carrying out minor maintenance work
• reporting problems with the production process or equipment to shift managers and maintenance engineers.

Much of the production process and machinery is computer-controlled, so more experienced operatives may work in a computer control room, supervising and monitoring the production run.

Hours and Environment

Chemical plant process workers commonly work shifts, including nights and weekends. Chemical processing plants are usually clean and well ventilated.

Workers wear protective overalls, glasses, helmets and boots.

Skills and Interests

To be a chemical plant process worker, you should:

• have an aptitude for science and technology
• have good computing, literacy and numeracy skills
• be able to work carefully, methodically and follow instructions 
• be able to concentrate during long periods of repetitive work
• be able to react quickly to problems
• have good communication skills
• be able to work in a team and on your own
• understand health and safety issues
• be reasonably physically fit.

Entry

You do not need any formal educational qualifications but some companies may ask for GCSEs (A-D)/S grades (1-4) in maths, English and science subjects. You may be asked to take numeracy and general aptitude tests and undergo a medical examination.

A common route for young people is to train as an apprentice. Most apprentices start at 16 to 19, but entry may be possible up to 24 (see the Training section for contacts). You will need four GCSEs (A-C)/S grades (1-3), such as maths, English, science, engineering, design and technology or appropriate equivalents.

Previous experience in manufacturing and processing industries can be useful.

For information about working in the chemicals industry, see the websites for Cogent and the Chemical Industries Association in Further Information.

Training

You receive training on the job, leading to work-based NVQ/SVQ awards, such as: 

• Bulk Liquid Warehousing Level 2
• Processing Operations: Hydrocarbons levels 1 to 3
• Polymer Processing and Related Operations levels 1 to 3
• Chemical, Pharmaceutical and Petro-Chemical Operations levels 1 to 3 (contains units in processing and control room operations) - there is a Level 4 award for technical and managerial staff.

These awards cover health and safety, emergency procedures, chemical processes, sampling, testing, first aid and basic machine maintenance.

Apprenticeships may be available for those under the age of 24. In England these are currently Apprenticeships (level 2) and Advanced Apprenticeships (level 3). To find out more about these, visit www.apprenticeships.org.uk

Apprenticeships may be different in other areas. For further information see Scotland , Wales and Northern Ireland

Opportunities

The chemicals industry is one of the largest manufacturing sectors in the UK, employing around 240,000 people. Employers range from big multinational chemical and oil companies to specialist small and medium-sized businesses.

The larger concentrations of employment are in the north-west, north-east, eastern England and the south-east, often located near ports, close to natural resources, or in major industrial centres close to potential customers.

Process operatives who train in technical skills like computer-control operations may be able to move into plant control, quality control, technical roles and supervisory management. See the profiles for Chemical Engineering Technician and Quality Control Technician.

Annual Income

Figures are intended as a guideline only.

Process operators start between £16,000 and £19,500 a year.
With experience and extra duties, this rises to between £20,000 and £26,500.

Some companies also offer overtime and productivity bonus payments.

Further information

Unit 5, Mandarin Court
Centre Park
Warrington
Cheshire
WA1 1GG
Tel: 01925 515200 Kings Buildings
Smith Square
London
SW1P 3JJ