Key Responsibilities and Required Skills for Unit Operations Engineer

🎯 Role Definition

The Unit Operations Engineer is responsible for designing, operating, troubleshooting and optimizing pilot-scale and production unit operations across chemical, pharmaceutical, food, and process-manufacturing environments. This role combines hands-on plant work, engineering design, data-driven process improvement, and cross-functional leadership to ensure safe, efficient scale-up and continuous operation of reactors, distillation columns, heat exchangers, filtration systems, pumps, and associated control systems. The ideal candidate brings strong process fundamentals, in-depth experience reading P&IDs, proficiency in process simulation and instrumentation, and a rigorous safety and quality mindset.

📈 Career Progression

Typical Career Path

Entry Point From:

Process Engineer (junior/associate)
Laboratory Engineer / Pilot Plant Technician
Chemical Engineer (co-op / intern transitioning to full-time)

Advancement To:

Senior Unit Operations Engineer / Lead Process Engineer
Process Engineering Manager / Unit Manager
Technical Fellow / Principal Engineer (process specialization)

Lateral Moves:

Process Safety Engineer
Production/Operations Manager
Scale-up/Technology Transfer Engineer

Core Responsibilities

Primary Functions

Lead the day-to-day operation, commissioning, and start-up of pilot plants and production units, ensuring safe, compliant, and efficient processing of raw materials through defined unit operations (reactors, distillation, extraction, dryers, filters, heat exchangers, evaporators, centrifuges).
Develop, execute and document experimental plans and scale-up campaigns for new processes and formulations, including detailed test protocols, sampling plans, mass and energy balance calculations, and acceptance criteria.
Troubleshoot mechanical, process, and control issues on unit operations equipment; diagnose causes, implement corrective actions, and validate performance improvements to minimize unplanned downtime and quality deviations.
Perform process optimization projects using data analysis, statistical methods (DOE), and process modeling to increase yield, throughput, energy efficiency, and product quality while reducing operating costs and waste.
Prepare and maintain accurate P&IDs, process flow diagrams (PFDs), standard operating procedures (SOPs), test instructions, and engineering change notices (ECNs) for unit operations to ensure consistent execution and regulatory readiness.
Lead HAZOP, PHA and process safety reviews for unit modifications, scale-up activities, and new equipment installations; implement mitigation actions and follow-up to ensure compliance with Process Safety Management (PSM) and local HSE standards.
Specify, select and qualify key process equipment and instrumentation (pumps, valves, heat exchangers, reactors, controllers, pressure relief devices), produce vendor specifications, and manage supplier technical evaluations and FAT/SAT activities.
Execute mass and energy balances, sizing calculations, heat transfer and residence time analyses to validate design assumptions and to support equipment upgrades or replacements.
Integrate control strategies with PLC/DCS engineers to optimize PID control loops, improve process stability, and implement automated sequences for safe start-up/shutdown and emergency response.
Lead root cause investigations (RCA) for process excursions, product quality failures, and reliability incidents using structured methods (5 Whys, fishbone), and drive corrective and preventive actions (CAPAs) to closure.
Collect, analyze and interpret process data using Excel, MATLAB, Python or statistical software; generate clear technical reports, run charts, and dashboards to communicate performance trends to operations and management.
Manage scale-up and technology transfer activities from R&D and pilot stages into manufacturing: write transfer packages, conduct pre-run reviews, train manufacturing personnel, and support first production campaigns.
Coordinate cross-functional teams (Operations, Quality, Maintenance, Instrumentation, Supply Chain) to align production schedules, spare parts, preventive maintenance plans and process capability improvements.
Implement and lead continuous improvement initiatives (Lean, Six Sigma) targeted at cycle time reduction, waste minimization, throughput increase and total cost of ownership reduction for unit operations.
Oversee calibration, preventive maintenance and reliability programs for process instrumentation and rotating equipment; prioritize spare parts, downtime mitigation plans, and vendor maintenance support.
Ensure sampling, testing and in-process controls meet QA/QC requirements and regulatory standards (cGMP where applicable); work with the quality team on batch investigations and deviation reporting.
Prepare capital and expense justifications for process upgrades and equipment replacements; develop project scopes, schedules, risk assessments and budget estimates, and support project execution through handover.
Train, mentor and supervise technicians, operators and junior engineers in safe unit operation, process fundamentals, SOP adherence and best practices for process improvement.
Maintain comprehensive technical documentation, change history, and lessons-learned records for pilot runs and production campaigns to accelerate future scale-ups and reduce rework.
Participate in emergency response and incident management for process upsets; provide technical leadership during shutdowns, turnarounds and commissioning to restore safe operations quickly.
Drive environmental and regulatory compliance for unit operations by managing waste streams, emissions control, and reporting related to local environmental permits and corporate sustainability goals.
Support product development by providing process feasibility input, manufacturability analysis, and cost-of-goods estimates to R&D and commercial teams during early-stage technical reviews.
Conduct lifecycle reliability and failure mode analyses (FMEA) for critical unit equipment to prioritize maintenance strategies and capital investments that improve long-term plant uptime.
Evaluate and implement new technologies and automation opportunities (advanced sensors, model predictive control, digital twin) to modernize unit operations and increase competitive advantage.

Secondary Functions

Support engineering and operations leadership with periodic KPI reporting and continuous improvement roadmaps for unit reliability and process capability.
Assist in procurement reviews and technical bid evaluations for complex equipment and engineering services.
Collaborate with environmental, health & safety teams to update operating permits and ensure unit operations adhere to local and federal regulations.
Participate in cross-site knowledge sharing and implementation of best practices for unit operations across the organization.
Provide subject-matter expertise during audits, customer visits and technical due diligence for potential partnerships or licensing.

Required Skills & Competencies

Hard Skills (Technical)

Thorough working knowledge of unit operations fundamentals: reactors (batch and continuous), distillation, extraction, absorption, filtration, crystallization, drying, heat transfer and mass transfer.
Ability to read, create and revise P&IDs, process flow diagrams (PFDs) and piping layouts; strong knowledge of instrumentation symbols and process control schematics.
Process simulation and modeling experience (Aspen HYSYS, Aspen Plus, PRO/II or similar) to support scale-up, debottlenecking and design verification.
Hands-on experience with PLC/DCS systems, PID loop tuning, and basic ladder logic or function block control concepts.
Proficiency with data analysis and statistical tools: Excel (advanced), Minitab, MATLAB, Python (pandas, numpy) or equivalent for DOE, regression and process capability studies.
Practical troubleshooting skills for rotating equipment, heat exchangers, pumps, compressors, valves and control valves including mechanical and instrumentation diagnostics.
Familiarity with Process Safety Management (PSM), HAZOP/HAZID methodology, and regulatory compliance frameworks (OSHA, EPA, cGMP when applicable).
Design and equipment specification skills, including preparing technical procurement documents, FAT/SAT criteria and vendor evaluation.
Experience with continuous improvement methodologies: Lean manufacturing, Six Sigma (Green/Black Belt preferred), and root-cause analysis frameworks.
Knowledge of mass and energy balance calculations, equipment sizing, thermal duty calculations and scale-up design factors.
Experience with laboratory-to-pilot-to-plant technology transfer and production troubleshooting during first-time manufacturing runs.
Competence using CMMS/EAM systems (SAP PM, Maximo or similar) to manage maintenance plans and spare parts.
Ability to prepare technical reports, engineering change requests, SOPs and batch records that meet quality and regulatory expectations.
Familiarity with safety relief system design, pressure vessel and piping codes (ASME), and relevant material compatibility considerations.
Working knowledge of control room practices, alarm management and advanced process control (APC) concepts is a plus.

Soft Skills

Strong analytical and problem-solving mindset with attention to detail and data-driven decision making.
Clear oral and written communication skills — able to translate technical concepts for operations, management and non-technical stakeholders.
Collaborative team player who can work across functional boundaries (R&D, QA, Maintenance, Procurement).
Proactive ownership and accountability for unit performance, safety and regulatory compliance.
Good project management skills: planning, prioritization, time management and ability to manage multiple initiatives concurrently.
Coaching and mentoring ability to develop operators and junior engineers.
Adaptability and resilience in fast-paced pilot plant or production environments with variable experimental schedules.
Safety-first attitude and demonstrated ability to instill a culture of operational discipline and process reliability.

Education & Experience

Educational Background

Minimum Education:

Bachelor's degree in Chemical Engineering, Mechanical Engineering, Process Engineering, or related engineering discipline.

Preferred Education:

Master's degree in Chemical Engineering, Process Engineering, or equivalent with focus on transport phenomena, reaction engineering or process design.
Professional certifications preferred: Six Sigma Green/Black Belt, Certified Process Safety Professional (CCPSC), PE (licensed Professional Engineer) where applicable.

Relevant Fields of Study:

Chemical Engineering
Mechanical Engineering (with process focus)
Process Systems Engineering
Industrial Engineering (with strong process/chemical coursework)

Experience Requirements

Typical Experience Range: 3–8 years of hands-on experience in unit operations, pilot plants or process manufacturing.
Preferred: 5+ years experience with demonstrated ownership of commissioning, scale-up, or continuous improvement projects; experience in regulated industries (pharma, biotech, food) or heavy chemical processing is a strong plus.