Torchora
Back to Home

Key Responsibilities and Required Skills for Unit Operations Intern

💰 $ - $

OperationsEngineeringInternshipManufacturingProcess Development

🎯 Role Definition

A Unit Operations Intern supports day-to-day operations of pilot plant or manufacturing unit operations under supervision. This role focuses on hands-on operation and optimization of process equipment (reactors, centrifuges, distillation columns, dryers, filtration systems, heat exchangers), sampling and analytical support, execution and documentation of standard operating procedures (SOPs), adherence to safety and GMP/GLP requirements, and collection/analysis of process data to support scale-up and process development initiatives. The Unit Operations Intern works cross-functionally with Process Development, Engineering, Quality, and Manufacturing teams and contributes to continuous improvement projects and technical reporting.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Undergraduate co-op or internship in chemical/biochemical engineering, process technology, or manufacturing operations
  • Laboratory Technician or Research Assistant roles in academic or industrial labs
  • Technical/production associate roles in manufacturing or pilot plants

Advancement To:

  • Unit Operations Technician / Process Technician
  • Process Development Engineer / Manufacturing Engineer
  • Scale-up Engineer or Pilot Plant Lead
  • Operations Supervisor or Production Manager

Lateral Moves:

  • Quality Assurance / Quality Control Associate
  • Automation/Controls Technician (PLC/HMI focus)
  • Supply Chain / Production Planning roles

Core Responsibilities

Primary Functions

  • Assist in the safe setup, start-up, operation, and shutdown of pilot-plant and bench-scale unit operations (reactors, centrifuges, dryers, filtration skids, distillation columns), following approved SOPs and process run plans while coordinating with operators and engineers.
  • Execute batch and continuous runs according to experimental matrices and production schedules, ensuring process parameters (temperature, pressure, flow, pH, agitation) are maintained within specified ranges and deviations are documented.
  • Perform routine and event-driven sampling, sample labeling, chain-of-custody, and delivery to analytical laboratories, and log results into LIMS or batch records as required.
  • Record detailed process data and observations in electronic lab notebooks, batch records, and run logs; prepare concise, accurate run summaries and handover notes for subsequent shifts or investigators.
  • Calibrate, set up, and verify basic instrumentation (pressure gauges, flow meters, RTDs, pH probes) and support field technicians in preventive maintenance and simple instrument troubleshooting to minimize downtime.
  • Carry out routine cleaning, sanitization, and CIP/SIP operations for process equipment and vessels in compliance with SOPs and safety procedures to maintain GMP/GLP cleanliness standards.
  • Follow all health, safety, and environmental procedures (PPE, confined space, lockout/tagout, chemical handling, waste disposal) and participate in safety inspections, near-miss reporting, and corrective actions.
  • Execute process experiments under the direction of Process Engineers and Scientists, including variable manipulation, run replication, and collection of process and quality metrics to support scale-up decisions.
  • Assist in the preparation of reagents, media, solvents, and process feeds using accurate measurements, weighing, and material handling techniques while maintaining inventory logs and material traceability.
  • Troubleshoot basic process upsets and abnormal conditions, escalate to senior engineers when necessary, and document root-cause observations to support continuous improvement and corrective action plans.
  • Support installation and commissioning activities for pilot equipment, including mechanical hookups, tubing, instrumentation installation, and verification testing under supervision of engineers and technicians.
  • Maintain and update SOPs, work instructions, and standard batch templates based on observed best practices and feedback from operations and QA to improve reproducibility and compliance.
  • Assist in scale-up studies by executing small pilot trials, carefully documenting scale-dependent variables, and compiling comparative data for process performance evaluation.
  • Participate in cross-functional shift handovers and coordination meetings with Manufacturing, Quality, Engineering, and Safety teams to ensure smooth transitions and alignment on priorities.
  • Execute small maintenance tasks such as gasket replacements, filter element swaps, minor mechanical adjustments, and housekeeping to support uptime and maintain a clean production environment.
  • Use basic process control and data acquisition tools (HMI/SCADA, PLC monitors, data historians) to monitor live process trends, export process logs, and flag deviations for engineering review.
  • Prepare materials, spare parts, and tooling for scheduled runs; stage equipment, pre-check utilities, and confirm raw material availability to ensure on-time execution of experiments or production runs.
  • Support quality investigations by providing accurate run records, sampling logs, instrument calibration certificates, and in-process observations to facilitate CAPA and deviation resolution.
  • Conduct simple analytical tests at the bench (pH, conductivity, turbidity, basic wet-chemistry assays) and coordinate with analytical labs for HPLC/GC or bioassays; log results and trends for process assessment.
  • Participate in continuous improvement projects (5S, kaizen, yield improvement) by collecting baseline metrics, testing proposed changes in pilot runs, and reporting measurable impacts on process efficiency and cost-per-unit.
  • Train under supervision on aseptic techniques, sterile transfers, and contamination control procedures (if applicable) to support biologics or aseptic manufacturing runs and maintain culture integrity.
  • Implement and follow environmental, health & safety and regulatory compliance tasks, including hazardous material handling, spill response readiness, and proper disposal of process wastes.
  • Communicate experimental outcomes and process observations in team meetings and contribute to technical reports, presentation decks, and post-run summaries for engineering review and decision-making.
  • Coordinate with procurement and inventory teams to report low stock on critical consumables (filters, seals, solvents) and assist in receiving and storing incoming materials per quality and safety requirements.

Secondary Functions

  • Support ad-hoc data requests and exploratory process data analysis by exporting run logs, summarizing trends, and creating simple visualizations (Excel/Graphing) to aid engineers and scientists.
  • Contribute to the organization's process documentation and data integrity efforts by ensuring accurate, complete, and timely electronic record-keeping.
  • Collaborate with business units to translate operational issues into engineering change requests or experiment designs that address performance gaps.
  • Participate in sprint planning, technical reviews, and agile-style problem solving within process development or operations teams to drive iterative improvements.

Required Skills & Competencies

Hard Skills (Technical)

  • Hands-on operation of pilot plant and bench-scale unit operations (reactors, filters, centrifuges, distillation equipment) — demonstrated ability to follow SOPs and safely execute equipment runs.
  • Basic process instrumentation and controls knowledge (PLC/HMI fundamentals, SCADA monitoring, data historians) to monitor, capture, and report process trends.
  • Familiarity with GMP/GLP principles, batch record documentation, and adherence to quality systems and regulatory requirements in manufacturing or process development environments.
  • Experience or coursework in sample handling and analytical techniques: HPLC/GC basics, wet-chemistry assays, pH/conductivity/turbidity measurements, and proper chain-of-custody practices.
  • Competence with electronic lab notebooks, LIMS, or other laboratory information systems for recording and retrieving process and analytical data.
  • Skill in data collection and basic analysis using Excel (pivot tables, charts, statistical summaries) or introductory scripting (Python/R) for data cleaning and visualization.
  • Practical knowledge of safety systems and procedures: lockout/tagout (LOTO), confined space entry, PPE selection, and hazardous material handling.
  • Ability to set up, calibrate, and perform basic verification of field instruments (pressure sensors, temperature probes, flow meters) and log calibration data.
  • Understanding of scale-up principles (heat/mass transfer, residence time, mixing) and how bench/pilot observations translate to larger-scale manufacturing decisions.
  • Familiarity with preventive maintenance concepts and basic mechanical skills (flange connections, gasket replacement, filter change-outs).

Soft Skills

  • Strong attention to detail and accuracy when executing runs, recording data, and maintaining batch records.
  • Clear verbal and written communication for effective handovers, deviation reporting, and cross-functional coordination.
  • Problem-solving mindset with the ability to escalate appropriately, propose root-cause hypotheses, and support corrective actions.
  • Teamwork and collaboration — comfortable working with engineers, scientists, QA, and manufacturing operators across shifts.
  • Time management and prioritization skills to balance multiple tasks such as setup, sampling, documentation, and cleanup during scheduled runs.
  • Adaptability and willingness to learn new equipment, processes, and software tools quickly in a fast-paced R&D or pilot environment.
  • Initiative and ownership — proactively identify opportunities to improve run reproducibility, process safety, and operational efficiency.
  • Strong safety mindset and commitment to follow and promote EHS standards at all times.
  • Analytical curiosity — ability to interpret process trends and support data-driven decision making.
  • Professionalism and reliability: punctuality, adherence to shift schedules, and responsible handling of sensitive materials and data.

Education & Experience

Educational Background

Minimum Education:

  • Currently enrolled in or recently graduated from a Bachelor's degree program (or higher) in Chemical Engineering, Biochemical Engineering, Chemical Technology, Mechanical Engineering, Chemistry, Biology, or closely related field.

Preferred Education:

  • Bachelor's or Master's degree in Chemical Engineering, Bioprocess/Chemical Technology, Biochemical Engineering, or related discipline with coursework in unit operations, process control, and thermodynamics.

Relevant Fields of Study:

  • Chemical Engineering
  • Biochemical / Bioprocess Engineering
  • Mechanical Engineering (with process focus)
  • Industrial Chemistry
  • Chemical Technology

Experience Requirements

Typical Experience Range:

  • 0–2 years (co-op/internship experience preferred). This is an entry-level role appropriate for students and recent graduates.

Preferred:

  • Prior laboratory, pilot plant, manufacturing, or process development internship experience.
  • Exposure to GMP/GLP environments, batch record keeping, and familiarity with LIMS or electronic lab notebook systems.
  • Hands-on experience with process equipment, basic instrumentation, and safety systems.
Explore More Careers