Key Responsibilities and Required Skills for a Kettle Technician

🎯 Role Definition

As a Kettle Technician, you are the cornerstone of our production process. You will be responsible for the end-to-end management of batch production within large-scale industrial kettles. This includes everything from material preparation and precise recipe execution to in-process quality control and equipment sanitation. Your expertise ensures that every batch meets our rigorous quality and safety standards, directly impacting product consistency and customer satisfaction. This position requires a high degree of mechanical aptitude, attention to detail, and a steadfast commitment to following established procedures in a fast-paced manufacturing environment.

📈 Career Progression

Typical Career Path

Entry Point From:

Production Associate or Assistant
Warehouse Operator or Material Handler
Junior Machine Operator

Advancement To:

Lead Kettle Technician or Senior Process Technician
Production Supervisor or Team Lead
Quality Control Supervisor

Lateral Moves:

Maintenance Technician
Quality Assurance (QA) Technician

Core Responsibilities

Primary Functions

Precisely operate and monitor industrial-grade kettles, mixers, and blending tanks to manufacture products according to detailed batch production records.
Accurately weigh, measure, and verify raw materials and ingredients using scales and meters, ensuring strict adherence to formulation specifications.
Execute complex manufacturing recipes, managing critical process parameters such as temperature, pressure, mixing speed, and cycle times through HMI or manual controls.
Conduct in-process quality control checks, including sampling, pH testing, viscosity measurement, and visual inspection, to ensure the batch meets all quality standards.
Meticulously complete and maintain accurate documentation, including batch records, logbooks, and inventory tracking sheets, ensuring full traceability and regulatory compliance.
Perform routine cleaning, sanitization, and sterilization of kettles, tanks, pumps, and associated piping, following stringent GMP and company SOPs (e.g., CIP/COP procedures).
Systematically troubleshoot process deviations and equipment malfunctions, making necessary adjustments to maintain product quality and operational efficiency.
Adhere to all established safety protocols, including Lockout/Tagout (LOTO), proper handling of chemicals, and use of Personal Protective Equipment (PPE).
Manage the transfer of finished products from kettles to holding tanks or filling lines, ensuring seamless production flow.
Operate material handling equipment, such as forklifts, pallet jacks, and drum lifts, to safely transport raw materials and finished goods.
Calibrate and perform minor adjustments on process equipment to ensure it operates within specified parameters and tolerances.
Monitor inventory levels of raw materials within the work area and communicate replenishment needs to the supply chain or warehouse teams.
Uphold Good Manufacturing Practices (GMP) and workplace organization standards (like 5S) to maintain a clean, safe, and efficient production environment.
Participate actively in preventative maintenance tasks in collaboration with the maintenance department to minimize downtime and extend equipment life.
Report any product quality issues, safety hazards, or equipment failures immediately to the Production Supervisor or Quality Assurance department.

Secondary Functions

Support ad-hoc data requests and exploratory data analysis to assist in process improvement initiatives.
Contribute to the organization's continuous improvement culture by suggesting enhancements to safety, quality, and efficiency.
Collaborate with R&D and engineering teams during the scale-up of new products or the implementation of new process technologies.
Participate in sprint planning, shift change meetings, and other agile ceremonies within the production team to ensure clear communication and alignment.
Assist in training new technicians on standard operating procedures, safety protocols, and equipment operation.
Perform environmental monitoring and swabbing as required to validate the effectiveness of sanitation procedures.
Assist in cycle counts and physical inventory verification to ensure accuracy of stock records.

Required Skills & Competencies

Hard Skills (Technical)

Industrial Equipment Operation: Proven ability to operate, monitor, and troubleshoot large-scale processing equipment like kettles, mixers, and pumps.
GMP & SOP Adherence: Strong understanding and practical application of Good Manufacturing Practices and Standard Operating Procedures in a regulated environment (e.g., food, pharma, cosmetics).
Basic Mechanical Aptitude: Ability to perform minor maintenance, troubleshoot equipment issues, and understand machinery functions.
Mathematical Proficiency: Skill in performing accurate calculations, conversions, and measurements for batching and record-keeping.
Forklift Operation: Certification or ability to become certified to operate forklifts and other material handling equipment safely.
Computer Literacy: Competence in using Human-Machine Interfaces (HMIs) and Manufacturing Execution Systems (MES) to control processes and record data.
Safety Protocol Knowledge: Expertise in industrial safety standards, including Lockout/Tagout (LOTO), chemical handling, and PPE usage.
Quality Control Testing: Experience with in-process testing tools for metrics like pH, viscosity, temperature, and specific gravity.

Soft Skills

Attention to Detail: Meticulous and precise in following complex instructions and documenting work to prevent errors.
Problem-Solving: Strong analytical skills to identify the root cause of process deviations and implement effective solutions.
Teamwork & Collaboration: Ability to work effectively with team members, supervisors, and other departments like Quality and Maintenance.
Time Management: Excellent organizational skills to manage multiple tasks and prioritize duties in a fast-paced environment.
Communication: Clear verbal and written communication skills for effective shift handovers, reporting issues, and documenting processes.
Adaptability: Flexibility to adapt to changing production schedules, priorities, and manufacturing processes.
Strong Work Ethic: A reliable, self-motivated individual who takes ownership of their responsibilities and is committed to quality outcomes.

Education & Experience

Educational Background

Minimum Education:

High School Diploma or GED equivalent.

Preferred Education:

Associate's Degree or certification from a technical/vocational school.

Relevant Fields of Study:

Process Technology
Manufacturing Technology
Chemistry or a related science

Experience Requirements

Typical Experience Range: 2-5+ years of hands-on experience in a manufacturing environment.

Preferred:

Direct experience as a Kettle Operator, Compounder, or Blender in the food & beverage, pharmaceutical, cosmetics, or chemical manufacturing industry.
Demonstrable experience working in a cGMP, FDA, or similarly regulated production facility.