What is a Process Technician and How Can You Become One?

In summary, think of it as making liquids, gases, powders or solids that have to be mixed, cooked, or fermented from a formula or recipe but on an industrial scale.

The end product is non-countable as in “How much?”

As such, process technicians generally work in the following sectors:

• Food and dairy
• Beer and whiskey manufacturing
• Chemical and petrochemical manufacturing
• Plastic manufacturing
• Agriculture processing
• Cosmetics
• Pharmaceutical and biopharmaceutical manufacturing
• Water treatment
• Mining and mineral processing (may be referred to as metallurgical/mineral process technicians

For a look at the role of a Process Technician as described by someone actually on the job, check out this video from the About Bioscience website, produced by the North Carolina Association for Biomedical Research

Equipment Operation and Monitoring

• Operate the control room for large industrial plants or refineries and monitor process output.
• Start up, monitor, or shut down plant equipment such as reactors, distillation columns, valves, compressors, pumps, and heat exchangers.
• Operate complex plant machinery and/or use software to run computer-operated processes on the factory floor.
• Read and monitor flow meters, temperature/pressure gauges, and other instruments.
• Take routine readings on process variables and material properties such as:
  • Density
  • Viscosity
  • Particle-size distribution
  • Flow rates
  • Pressures
  • pH levels
  • Cell count (especially in biomanufacturing)
  • Temperature
• Make manual or automated adjustments to equipment settings based on data readings.
• Regularly review the production schedule to ensure equipment is aligned with demand.

Process Optimisation

• Understand the chemical manufacturing process in detail to recognize deviations from normal operation.
• Identify inefficiencies or variances and take corrective actions within your scope.
• Escalate when problems persist or are outside technician-level control.
• Monitor equipment and process performance for signs of wear or drift that could impact efficiency.
• Optimize flow paths and batching sequences to reduce downtime and improve yield (especially in batch manufacturing environments).

Troubleshooting

• Quickly diagnose and troubleshoot routine or minor process or equipment problems.
• Adjust equipment settings, swap components, or flush systems as necessary to restore functionality.
• Monitor for warning signs that may indicate underlying issues.
• Involve senior staff (e.g., process engineers or maintenance leads) when encountering more complex or unresolved issues.
• Contribute to root cause analysis after failures or quality deviations by providing accurate data and observations.

Quality Control

• Collect product samples for laboratory testing at key stages in the process.
• Measure and weigh materials before processing to ensure batch accuracy.
• Mix chemical reagents to precise specifications.
• Monitor in-process quality attributes such as temperature, pH, viscosity, and cell counts.
• Report any anomalies or process inconsistencies that could compromise product quality.

Note: In regulated industries like pharmaceuticals, any deviation in quality may require full batch disposal.

Documentation

• Maintain clear and accurate batch records, including process parameters, material inputs, and production time stamps.
• Record equipment readings, adjustments, and actions taken in logbooks or digital systems.
• Gather process data and report it to senior staff such as Process Engineers or Production Managers.
• Ensure documentation is audit-ready and compliant with internal and external standards.

Following Protocols

• Strictly follow internal protocols and Standard Operating Procedures (SOPs) for each step of the process.
• Comply with external regulatory standards such as:
  • cGMP (current Good Manufacturing Practice)
  • FDA or EMA regulations (for pharmaceutical manufacturing)
• Use appropriate personal protective equipment (PPE) and adhere to site-specific safety requirements.
• Follow procedures for cleaning, sterilization, and handling of materials to prevent cross-contamination.

Cleaning and Maintenance

• Clean spills safely and according to hazard classification.
• Sterilize equipment between production batches, especially in sterile manufacturing environments.
• Perform routine inspections, maintenance, and minor repairs on equipment as per operational instructions.
• Notify maintenance teams or engineers when major servicing is needed.

We also see “Process Operator” to describe an entry-level version of this role where they place heavy emphasis on strictly following processes, procedures and systems so you generally wouldn’t need a chemistry, engineering or science background.

Some companies call this role:

• Process Operative
• Chemical Process Operator
• Chemical Plant and System Operator
• BioProcess Operator
• BioProcess Manufacturing Operator
• Cleanroom Operator

A high school/secondary school or equivalent qualification along with the right aptitude and skills is sufficient. Employers typically provide the training needed to complete the tasks specific to each job role as necessary.

Entry-level salaries range from €30,000 – €40,000 plus overtime, bonuses and shift allowances (up to 30% extra). (Based on Morgan McKinley Irish Salary Calculator)

Process Technicians may spend a lot of time at a control desk in a large industrial plant or they could always be on their feet on the industrial plant floor. Even when they are operating or monitoring a machine, they are still standing and alert. Many work in controlled environments with restricted access.

Process Technicians can work:

• outside, (petrochemicals, oil refineries, fertilizer manufacturing)
• within a hygienic environment (food & beverage, beer, cheese)
• within a  cleanroom environment  (pharmaceutical, biopharmaceutical or medical device manufacturing)

In some cases, the role may require a high degree of manual dexterity as the job might require switching out pipes, plant or machinery when changing from one product run to another within the facility.

Depending on the environment, personal protective gear (including masks, cleanroom gowns, clothing, footwear, and gloves) is required. This is both for their own safety and to maintain the integrity of the product by avoiding contamination.

In biopharmaceutical manufacturing, processes technicians could work in:

• Upstream operations – stages of biopharmaceutical processing up to the cell culture or fermentation process that is used to make the target proteins
• Downstream operations – stages of processing that come after cell culture or fermentation. These stages include separation and purification to achieve the required drug product
• Manufacturing, science & technology (MSAT) – support operations with activities such as continuous process improvement, implementing new technologies and troubleshooting
• Fill finish/packaging – final stages of the manufacturing process where the active agent is prepared into its final form, before being filled and sealed within containers.

Process technicians can advance to roles with more responsibility, such as:

• Senior Process Technician: Overseeing a team of technicians and managing more complex processes.
• Production Supervisor: Managing the overall production process and team.
• Process Engineer: Designing and and running new process engineering plants. Typically requires going back to university to get a chemical engineering degree

Most process technician roles would typically require some training in chemical engineering or relevant chemistry or biochemistry qualification. This could be an associate degree/diploma in chemical/process engineering, science or a related field or vocational training through an accredited institution.

However, this is not an absolute requirement. We have come across companies that hire people as process operators, invest time and money in building up their responsibilities to that of a process technician and even pay for them to go to university to become chemical/process engineers.

Here is an example of a typical curriculum taken from University College Cork in Ireland or a process and chemical engineering diploma.

• Introduction to Chemical Processing Engineering
• Material and Energy Balances
• Fluid Mechanics and Particle Processing
• Heat Transfer and Applied Thermodynamics
• Mass Transfer and Separation Processes
• Process Control and Equipment Integrity
• Process Optimisation and Occupational Health and Safety
• Environmental Engineering and Safety
• Reaction Engineering and Unit Operations
• Process and Plant Design
• Chemical Engineering Project

If you’d like to retrain for a process technician role within the pharmaceutical manufacturing sector, check out the following steps;

STEP 1: take this Conversion Course into Pharma to retrain for starter-level roles such as:

• Process Operator. Some companies call this role:
• Cleanroom Operator
• Chemical Plant and System Operator
• Chemical Process Operator

View Salaries

STEP 2: If you want to progress your career beyond a starter role and beyond, then take our Certificate in eBioPharmachem program to get a level 7 university qualification from the Technology University Dublin, Ireland and get better jobs with a higher salary. Typical roles;

• Process Technician
• Chemical Process Technician,
• BioProcess Technician

And with more experience:

• Production Supervisor
• Quality Assurance Specialist
• Documentation Specialist
• Validation Technician
• CQV Technician

Technical Skills

• Knowledge of process equipment, instrumentation, and control systems.
• Chemistry or chemical engineering knowledge (sector-dependent, sometimes learned on the job), including:
  • Plant design and commissioning
  • Phase equilibrium and mass transfer
  • Biochemical engineering
  • Industrial chemistry
  • Organic chemistry
  • Cell biology
  • Reactor design
  • Chemical reaction engineering
  • Process dynamics and control
  • Chemical process equipment
  • Unit operations and particle technology
• Be able to read and interpret technical drawings, especially P&IDs and pipe skids.
• Good computer skills — many systems for process control and documentation are digital.

Problem-Solving

• Ability to analyze problems and develop effective solutions.
• Systems analysis and evaluation to identify root causes and process improvements.
• Calm under pressure — able to take appropriate action and escalate when necessary.
• Alert — must quickly identify when the process is deviating from the norm.

Attention to Detail

• Ensuring accuracy in data collection, documentation, and quality control.
• Familiarity with many-step procedures and the importance of following SOPs precisely.
• Observing all elements of a cleanroom or controlled environment thoroughly.

Communication Skills

• Effectively communicating with team members, engineers, and supervisors.
• Strong written communication skills for clear and compliant documentation.
• Active listening and clear verbal communication — especially critical during high-pressure situations.

Teamwork

• Collaborating with others to achieve production goals.
• Sharing process insights and observations with engineers or senior staff to support continuous improvement.

Additional Core Skills

• Good at gathering information through observation.
• Numerical skills — important for following protocols that include formulas and quantitative measurements.

For more information on currently available Process Technician roles, head to our pharmaceutical jobs board for Ireland and our pharmaceutical jobs board for the UK and select Production/Manufacturing in the “Jobs by Category” menu.

Manufacturing/Production

• Process Technician
• Process Operator
• Manufacturing Technician
• Production Operator
• Packaging Operator
• Production Supervisor

Engineering

• Process Engineer
• Manufacturing Engineer
• Instrumentation Engineer
• Project Engineer
• Automation Engineer

Maintenance

• Facilities Engineer
• Calibration Technician
• Maintenance Technician

Quality

• Quality Engineer
• Documentation Specialist
• Quality Assurance Specialist
• Quality Control Analyst

Science/Laboratory

• Biochemist
• Laboratory Technician
• Microbiologist

Validation

• Validation Engineer
• CQV Engineer
• Validation Technician
• Computer System Validation (CSV) Engineer