Key Responsibilities and Required Skills for Isolate Reactor Operator

🎯 Role Definition

We are hiring an Isolate Reactor Operator — a mission-critical production role responsible for operating batch reactors and executing the isolation and transfer steps that convert reaction intermediates into finished product streams. The ideal candidate is a detail-oriented operator with strong process discipline (cGMP/SOP), hands-on experience with reactor charge/discharge and CIP/SIP procedures, and a proven track record of safe, compliant batch execution and accurate batch record documentation. This role frequently interfaces with Quality, Maintenance, and Engineering teams to ensure product quality, uptime and regulatory compliance.

📈 Career Progression

Typical Career Path

Entry Point From:

Chemical Operator
Production Technician
Laboratory Technician (with process or pilot plant exposure)

Advancement To:

Senior Reactor Operator / Lead Operator
Shift Supervisor / Production Supervisor
Process Engineer (with additional education)
Production Manager / Operations Manager

Lateral Moves:

Quality Control Analyst / QC Technician
Maintenance Technician / Mechanical Specialist
Process Safety Specialist

Core Responsibilities

Primary Functions

Operate, monitor and control batch reactors and associated peripheral equipment (agitators, jackets, condensers, feed/pump systems) to execute reaction and isolation steps according to approved batch records and SOPs.
Execute reactor charge, heat/cool profiles, hold times, and controlled additions, ensuring parameters (temperature, pressure, pH, flow, RPM) remain within defined limits and documenting all deviations.
Perform product isolation tasks including phase separations, decanting, filtration, centrifuge operations, solvent exchanges, and intermediate transfers while ensuring sample collection and chain-of-custody for QC testing.
Complete accurate and legible batch records and production logs in real time; record all reagent lot numbers, quantities, weights and analytical results required for release.
Set up, validate and run CIP/SIP cycles for reactors, transfer lines and tanks; verify clean and sterile conditions per SOPs and cleaning validation procedures before reuse.
Execute safe reactor startup and shutdown procedures, including isolation valves, vents, inerting (nitrogen/argon), and blanketing, following lockout-tagout (LOTO) and permit-to-work requirements.
Operate and interpret basic process control systems (PLC/SCADA/HMI) to monitor reactor alarms, setpoints and recipe execution; escalate control issues to Automation/Engineering when needed.
Troubleshoot process upsets, abnormal noise/vibration, flow restrictions and heat transfer problems; perform root-cause oriented corrective actions and enter details in deviation reports.
Manage hazardous materials handling and solvent transfers, including use of drum pumps, tanker offload procedures, and secondary containment to minimize spill risk and environmental impact.
Carry out in-process sampling and rapid QC checks per sampling SOPs; deliver samples to QC with proper documentation and support follow-up actions as required.
Coordinate with Maintenance for rapid repair of agitators, seals, valves and pumps to minimize downtime while observing equipment isolation and safety practices.
Follow and enforce cGMP, OSHA, EPA, and company-specific safety, hygiene and environmental protocols; participate in safety meetings, HAZOPs and continuous improvement initiatives.
Conduct line clearances and handoffs to adjacent operations (filtration, downstream isolation, packaging) ensuring complete documentation and clearance of residual materials.
Participate in changeover procedures between products including product purge, line reclamation, and cross-contamination prevention measures; document reconciliation of materials and consumables.
Verify reagent prep and dosing calculations, weigh raw materials accurately, and prepare/extinguish reagent additions (dilutions, pre-mixes) as described in work instructions.
Support validation and qualification activities: execute protocol steps, collect data, and sign off IQ/OQ/PQ tasks under supervision of Engineering/Validation.
Maintain inventory records for solvents, catalysts and reagents used in reactor operations; initiate reorder requests and manage stock rotation to avoid out-of-spec materials.
Train and mentor new operators on reactor-specific SOPs, safety protocols, batch execution and documentation expectations; help build a culture of compliance and continuous improvement.
Lead or support incident investigations and CAPA implementation related to reactor or isolation issues; summarize findings and ensure corrective actions are closed and verified.
Carry out basic preventative maintenance tasks (lubrication, seal checks, alignment verification) and collaborate with Maintenance to schedule planned downtime for major repairs.
Ensure proper waste segregation, labeling and disposal of process residues and solvents in accordance with environmental and hazardous waste regulations.
Maintain clear communications with Shift Lead, Quality and Process Engineering during critical operations, escalations and product holds to minimize business impact and maintain product integrity.

Secondary Functions

Participate in process improvement projects to optimize yield, reduce solvent use and shorten isolation cycle times using Lean/Six Sigma tools.
Support documentation updates by proposing SOP clarifications and contributing to batch record simplification initiatives.
Assist Quality in investigations by supplying historical batch data, operator notes and trend observations that may aid root cause analysis.
Cross-train on adjacent production areas (filtration, distillation, downstream finishing) to improve operational flexibility and coverage.
Support pilot trials and scale-up activities by executing small-batch runs and providing operator feedback to Process Development teams.
Contribute to emergency response drills (spill response, fire, confined space) and maintain required certifications and training records.

Required Skills & Competencies

Hard Skills (Technical)

Proven operation of batch chemical reactors and associated equipment (stirrer/agitation, heat transfer jackets, condensers, vacuum systems, filtration).
Knowledge of batch process control systems (PLC, SCADA, HMI) and basic ability to navigate recipes, alarms and trend data.
Strong understanding of cGMP and regulatory compliance for pharmaceutical or high-purity chemical manufacturing.
Hands-on experience with CIP/SIP systems, sterile/aseptic cleaning practices and cleaning validation basics.
Proficiency in reading and executing SOPs, batch records, P&IDs, process flow diagrams and material safety data sheets (SDS).
Competence with lockout-tagout (LOTO), confined space entry, and permit-to-work systems.
Experience with hazardous materials handling, solvent management, and chemical spill response.
Familiarity with sampling techniques and chain-of-custody procedures for in-process and release testing.
Basic mechanical aptitude for routine troubleshooting of pumps, seals, valves and agitators.
Ability to perform accurate weighing, volumetric transfers and stoichiometric calculations for reagent preparation.
Experience with deviation reporting, CAPA documentation and participation in compliance investigations.
Working knowledge of process validation principles (IQ/OQ/PQ) and involvement in execution or data collection.
Proficiency with electronic batch record systems, computerized manufacturing execution systems (MES) or paper-based documentation.
Basic data interpretation skills: reading lab results, trending temperature/pressure/time data and acting on out-of-spec indicators.

Soft Skills

Strong attention to detail and commitment to accuracy in both process execution and documentation.
Excellent verbal and written communication skills for cross-functional coordination with Quality, Maintenance and Engineering teams.
Problem-solving mindset with the ability to remain calm and methodical during process upsets or unexpected deviations.
Reliable, accountable and able to own shifts and handoffs with minimal supervision.
Team player who mentors peers, participates in shift turnover and contributes to a collaborative safety culture.
Adaptable to rotating shifts, overtime and periodic maintenance windows as required by production schedules.
Good time-management skills to balance multiple simultaneous tasks during critical batch windows.
Continuous improvement orientation; open to training, feedback and process optimization.
Situational leadership when guiding less experienced operators during complex or high-risk steps.

Education & Experience

Educational Background

Minimum Education:

High school diploma or GED required.

Preferred Education:

Associate Degree in Chemical Technology, Applied Science, Process Technology, or related field preferred.
Bachelor’s degree in Chemical Engineering or Chemistry advantageous for advancement.

Relevant Fields of Study:

Chemical Technology / Process Technology
Chemical Engineering / Engineering Technology
Applied Science / Industrial Chemistry
Pharmaceutical Sciences / Bioprocessing

Experience Requirements

Typical Experience Range:

2–5 years of hands-on experience operating reactors or performing isolation/filtration tasks in chemical or pharmaceutical manufacturing.

Preferred:

3+ years of direct reactor/batch processing experience in a GMP-regulated environment with documented experience in batch record compliance, CIP/SIP operation, and process troubleshooting.
Prior exposure to PLC/SCADA systems, SOP development, and participation in validation or process improvement initiatives preferred.