Polymer processing technicians work in the process manufacturing sector.
A polymer is a substance or material made of long repeating chains of molecules. There are several types of polymers. They have different properties: light, heavy, strong, tough, and flexible, depending on the type of molecules bonded and how they are bonded. They are used for a wide variety of purposes in both everyday consumer products and highly demanding technical applications. Elastomer and rubber for example, are used for tyres and components such as seals and gaskets. PVC is used for water pipes, window frames, and cable insulation. Nylon and polyester are used in clothing. And plastics are used in mobile phones, computer hardware, automotive, medical devices, aerospace, disability aides, water bottles, and vacuum cleaners.
Polymer processing technicians produce polymer products to a specification. They work in a production facility - often on a large scale, using a range of machinery, control systems and engineering equipment. Products are made using continuous or in batch processes. Polymer processing technicians set up or configure equipment and tooling and prepare materials for processing. They run and monitor the process, adjusting parameters. They use unique technologies and processes such as extrusion, blow moulding, thermoforming, rotational moulding, injection moulding, internal mixing, and calendering. They undertake quality control, complete work records, and participate in improvement. They may also complete preventative maintenance and prepare polymer process equipment for maintenance and overhaul.
They work with other members of the production team. They also have contact with people from other functions such as, process engineers, maintenance engineers, laboratory staff, supply chain staff, and warehouse staff. They may also have contact with external people such as customers, service providers, suppliers, and regulators. They usually report to a production manager.
They must ensure that the process and products meet quality specifications and are produced to schedule. They must comply with health and safety regulations and procedures including wearing personal protection equipment (PPE). They also need to meet environmental and sustainability regulations and procedures – minimising waste and recycling materials. They may work as part of a small or large manufacturing team. They work with minimal supervision and are responsible for the quality of their own work. They may work shifts.
Polymer process technician
Polymer processing technician
Process technician
Production technician
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Duty 1 Prepare polymer equipment and materials for processing. For example, complete tool changes, set machine parameters. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K27 K28 K33 K39 |
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Duty 2 Run and monitor polymer processes, adjusting parameters such as speed, temperature, pressure, and time. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K25 K27 K28 K34 K35 K39 |
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Duty 3 Complete secondary operations such as assembling, printing, decorating, cooling operations, packing, and labelling. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K20 K21 K23 K25 K26 K27 K28 K34 K39 |
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Duty 4 Complete quality control processes. For example, conduct grade parameter checks (size, colour, weight). Take samples for laboratory testing. Perform material testing (melt flow index (MFI), moisture, tensile etc). |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K27 K28 K29 K35 K36 K39 |
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Duty 5 Resolve process, quality and operating environment issues when operating out of normal parameters. For example, out of specification parameter. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K27 K28 K29 K33 K35 K36 K38 K39 K40 K41 K42 |
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Duty 6 Conduct handover responsibilities - providing information to or receiving information from other shifts or maintenance teams. |
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Duty 7 Complete process documentation - digital or paper based. For example, process and production records, traceability records, quality assurance records. |
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Duty 8 Maintain the work area (housekeeping) following safety, environmental and risk management systems. Ensure waste is separated, segregated, and handled in accordance with environmental standards. |
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Duty 9 Establish a process involving new or modified equipment, tooling or material and report on the outcomes. Carry out process trials and capability studies. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K27 K28 K29 K33 K34 K35 K38 K39 K40 K41 K42 K43 |
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Duty 10 Conduct first line routine maintenance (daily and preventative) and testing of polymer processing equipment. For example, checking guarding, lubrication, cleaning of tooling, safety checks, and inspection for wear and tear. |
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Duty 11 Prepare polymer process equipment for maintenance and overhaul. |
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Duty 12 Support internal audits to ensure regulatory compliance. |
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Duty 13 Participate in continuous improvement activities. For example, identifying ways to contribute to sustainability by reducing energy use and waste, improving cycle times, tool trialling. |
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K28 K29 K32 K33 K34 K35 K37 K38 K39 K40 K41 K42 K43 |
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Duty 14 Participate in risk assessment activities. |
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Duty 15 Participate in root cause investigations for quality related issues and implement the corrective action to ensure that failures are non-repeatable and production is ongoing. |
K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14 K15 K16 K17 K18 K19 K20 K21 K22 K23 K24 K25 K26 K27 K28 K29 K35 K36 K37 K38 K39 K40 K41 K42 |
K1: Polymer industry awareness: range of polymer products, manufacturing environments, types of customers.
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K2: Polymer process technician’s role. Limits of responsibility. Escalation procedures.
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K3: Health and safety regulations, standards, and guidance. Control of Substances Hazardous to Health (COSHH). Electrical safety and compliance. Emergency procedures. Fire safety. Health and Safety at Work Act – responsibilities. Incident and near miss reporting and investigation. Lifting Operations and Lifting Equipment Regulations (LOLER). Legionella. Lone working. Management of health and safety at work. Manual handling. Noise regulation. Permits to work. Provision and Use of Work Equipment Regulations (PUWER). Safety signage and purpose. Slips trips and falls. The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR). Working at Height.
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K4: Health, safety, and environmental practice. Polymer manufacturing safety hazards – risks they pose and their management: temperature, pressure, and fumes. Polymer processing safety guidance. Risk assessment and safe systems of work. Personal Protective Equipment (PPE) requirements. Resource reuse, recycling, and waste handling procedures.
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K5: Environmental and sustainability regulations, standards, and guidance. Environmental hazards that can arise from polymer operations. Environmental management systems standard. Environmental Protection Act. Environmental signage and notices. Carbon footprint of different types of polymers and materials used in production: how that can be mitigated for by selection and whole of lifecycle considerations.
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K6: Principles of sustainability and circular economy. Energy efficiency and reuse of polymers. Principles of control and management of emissions and waste.
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K7: Chemical terms associated with polymers: element, atomic mass, molecule, functional group, monomer, oligomer, polymer, polymerisation, molecular weight, molecular weight distribution, bonding, and tacticity.
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K8: Polymerisation processes: addition polymerisation, condensation polymerisation, catalyst, conditions. Sources of chemical materials; crude oil derived and bio-materials.
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K9: Thermal characteristics of polymers: glass transition temperature, melting temperature, processing temperature, specific heat, heat capacity, heat distortion temperature, melt density, thermal stability.
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K10: Classes of material: thermoplastics, thermosets, elastomers, rubbers, thermoplastic elastomers, commodity, engineering and high-performance materials, molecular structure, blends, and alloys.
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K11: Rheology behaviour: viscosity, shear stress, shear rate, newtonian flow, non-newtonian flow, viscosity-temperature relationships, flow measurement methods and indexes.
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K12: Key differences in processing different classes of polymers: melt processing, malleable state forming, cooling, and curing processes, importance and influence of controlling cooling and curing aspects of polymer processing.
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K13: Influence of morphology on physical and mechanical properties of polymers.
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K14: Polymer materials: definition, classifications, properties, applications, products, and terminology.
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K15: Factors affecting the glass transition temperature of polymers.
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K16: Factors affecting the degree of crystallinity of polymers: molecular and processing.
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K17: Material data sheets, understanding test methods and data reported; physical, mechanical, thermal, optical, electrical, flammability properties of polymers.
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K18: Formulating ingredients: reinforcing and non-reinforcing fillers (glass fibre, carbon black), mineral oils, plasticisers, flame retardants, additives (antioxidants, UV absorbers, antiozonants, slip additives, lubricants, anti-static agents, anti-fog), thermal stabilisers, processing aids, curing agents (sulphur, peroxides, phenolics), colourants, flame retardants, impact modifiers, coupling agents, release agents, anti-microbial, fungicides and biocides, scavengers, detectable, anti-counterfeit, and biodegradable. Purpose, benefits, and limitations.
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K19: The impact of re-used and re-cycled polymers on the processing conditions and final product properties.
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K20: Continuous and batch techniques. Production requirements: product specification, processing specification, rate of production. Material safety data sheet, product labelling and product codes; the importance of identifying non-conforming materials and products. Manufacturing control. Overall Equipment Effectiveness (OEE). Stock control.
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K21: The basic parts and functions of polymer processing plant and equipment: pneumatic and hydraulic systems and components, mechanical systems, electrical and electronic systems and components, heating and cooling arrangements, machine controls, material delivery and collection systems, guards and safety devices, cutting and forming, and service supply and connection methods, and support services.
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K22: Types of mould tools, formers and dies: purpose, features, construction, materials, damage and non-conformance checking requirements, and mounting methods (bolts, clamps, quick release).
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K23: Polymer processes and techniques: extrusion (polymer compounding, profile, film, filament, sheet, wire, and cable) injection moulding, blow moulding, compression moulding, rotational moulding, processing of polyurethane, thermoforming, internal mixing of polymer compounds, milling (two roll mill), calendaring, manual and automated layup techniques for elastomers, 3D Printing.
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K24: Polymer processing material preparation requirements: formulations, drying, weighing, conveying, mixing, blending, and colouring of polymers.
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K25: Machine operating parameters: temperature, pressure, speed or timings, and distance. Impact of changes on the quality of the components. Adjustments required to resolve issues.
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K26: Polymer post processing techniques: assembling, printing, decorating, cooling operations, packing, and labelling.
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K27: Standard operating procedures: their purpose and why they are important, how they are developed and maintained.
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K28: Quality, cost, and delivery (QCD) standards and their importance in the workplace.
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K29: Quality assurance, testing, inspection, and sampling methods. Process and control systems.
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K30: Documentation requirements: documentation control, auditable records.
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K31: Purpose of audits and why they are important.
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K32: Preventative maintenance strategy and practice.
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K33: British standards for engineering representations, drawings, and graphical information.
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K34: Application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and 3D printing.
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K35: Data analysis methods and techniques.
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K36: Problem solving and fault-finding techniques: root cause analysis, 5-Whys.
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K37: Continuous improvement (CI) methodologies and tools: lean, KAIZEN, 5S, workplace organisation.
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K38: Information and digital technology. Document sharing platforms, email, management information systems, spreadsheet, virtual learning platforms, word processing, process and control systems, presentation software. General data protection regulation (GDPR). Cyber security.
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K39: Planning, prioritising, and time management techniques.
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K40: Principles of team working. Equality, diversity and inclusion.
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K41: Verbal communication techniques.
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K42: Written communication techniques. Report writing techniques.
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K43: Presentation techniques.
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S1: Review instructions or information. For example, work instructions, sampling requirements, drawings dimensioning, labelling, formulations, machine settings.
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S2: Plan task and identify and organise resources with consideration for safety, environmental impact, security, quality and cost.
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S3: Identify and document hazards and risks in the workplace.
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S4: Apply health, safety, and environmental procedures in compliance with regulations and standards. For example, daily machine checks, wearing personal protective equipment.
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S5: Apply sustainability principles for example, in choice of materials, minimising waste.
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S6: Segregate resources for reuse, recycling, and handling.
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S7: Select, check, and prepare materials for polymer processing for example, weighing, control and blending, and conditioning.
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S8: Select, configure (for example, replace or change inserts) and check mould tools, formers, dies or other process equipment.
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S9: Check installation and function of processing equipment for the process.
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S10: Connect service connections such as water, electrical, pneumatic, hydraulic.
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S11: Check hand tools, equipment and machinery including calibration record where applicable.
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S12: Set or check machine settings using instructions such as temperature, pressure, speed or time, distance.
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S13: Adjust machine setting for the speeds, positions, pressures and safety of the mould tool, former or die movement to meet product specification.
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S14: Start up manufacturing processes.
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S15: Monitor process feedback and adjust process parameters.
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S16: Shut down manufacturing processes.
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S17: Devise machine settings such as temperature, pressure, speed or time, distance for new or modified equipment, tooling or material.
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S18: Test and evaluate machine settings for new or modified equipment, tooling or material.
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S19: Select and apply optimal machine settings for new or modified equipment, tooling or material (for example, capability study).
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S20: Interpret data for example, process data, quality control and test procedure data. Use data to inform action.
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S21: Identify process faults and resolve.
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S22: Apply post processing techniques for example, assembly, printing, decorating, cooling operations, packing, and labelling.
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S23: Follow quality assurance processes during manufacture.
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S24: Perform quality control checks. For example, conduct parameter checks (size, colour, weight), and take samples.
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S25: Identify quality issues and resolve for example, defects, maintenance requirements.
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S26: Escalate issues outside limits of responsibility.
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S27: Apply preventative maintenance practices. For example, checking guarding, lubrication, cleaning of tooling, safety checks, and inspection for wear and tear.
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S28: Apply continuous improvement techniques. Devise suggestions for improvement. For example, improving the effectiveness of existing production, improving the energy consumption or waste profile of processes and procedures to improve the sustainability or carbon footprint of a product, process or task.
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S29: Apply team working principles.
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S30: Communicate with others verbally for example, colleagues and stakeholders.
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S31: Record or enter information - paper based or electronic. For example, process and production records, traceability records, and quality assurance records.
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S32: Present information.
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S33: Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests, technical reports.
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S34: Use information and digital technology. Comply with GDPR and cyber security regulations and policies.
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S35: Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made.
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B1: Prioritise health, safety, and the environment.
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B2: Consider the environment and sustainability when using resources and carrying out processes.
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B3: Take responsibility for the quality of their own work.
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B4: Team-focus to meet work goals including a commitment to equality and diversity.
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B5: Respond and adapt to work demands.
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B6: Committed to continued professional development.
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English and maths qualifications must be completed in line with the apprenticeship funding rules.
This standard aligns with the following professional recognition:
| Version | Change detail | Earliest start date | Latest start date |
|---|---|---|---|
| 1.0 | Approved for derlivery | 09/08/2023 | Not set |
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