How are production employees deployed in the chemical industry?

The chemical industry is the branch of industry in which chemical products are manufactured. These products then form the starting materials for the production of many other branches of industry. These include raw materials for the production of plastics, textiles, pharmaceuticals, fertilizers, and much more.

As a supplier of important raw materials, the chemical industry itself is a driving force for the economy and innovation in many sectors. It often obtains its raw materials from oil refineries, but also from other sources. Sustainability is becoming increasingly important today, which is also reflected in the work of production employees. Greater emphasis is being placed on efficiency, and more recycled materials are being used. There is also an increasing focus on reducing various emissions during production.

Estimated reading time: 29 minutes

What are the work areas for production employees in the chemical industry?

In the production of chemicals, the working areas of Production employees are also widely diversified. This is because machines and systems are used here as well. Raw materials must be processed, products bottled, packaged, and stored and there is also quality control.

Generally speaking, this means that production employees work in raw material conversion and processing, for example. They receive raw materials and mix them. To do this, they follow complex recipes to achieve the desired properties in the substances.

They also operate and monitor the machines, of which there are many in the chemical industry. This is necessary to produce the required volumes at the desired quality level.

Quality control is present from delivery through to the packaged end product. However, more work is done here than in other sectors by taking and analyzing samples. These are examined in laboratories to ensure that each step has produced the intended results.

What do production employees do in packaging and storage?

Packaging and storage, in turn, involve preparing and storing the finished products. It is important to ensure that suitable containers are used, as the properties of various chemicals can damage inappropriate packaging. Care must also be taken to ensure that proper storage conditions are maintained. This is necessary both because of potential risks and in regard to the shelf life of stored end or intermediate products. These are often chemically active and may react with their environment under unfavorable conditions. They may either damage their surroundings or alter or lose their own properties.

In the chemical industry, there is also auxiliary work carried out by production employees or assistants. This includes preparing materials for production. Work areas, machines, and tools must also be cleaned. Equipment and systems must be serviced and maintained, so production workers are also needed in this area.

What professions are there in the chemical industry?

The professions in the chemical industry are aligned with these tasks.

• This begins with the chemical production specialist, who is responsible for monitoring and controlling production processes. They also perform various laboratory tests.
• Then there is the chemical assistant, who carries out basic tasks in production, including operating various machines and systems.
• Another profession is the chemical technician, who is trained in production and processing procedures. They work in the chemical industry and are also responsible for maintaining and servicing equipment such as reactors, pumps, or distillation columns.
• A pharmaceutical technician also works in this area. They operate specialized machinery used in the production of capsules, tablets, and ointments.

What work do production employees do in the chemical industry?

Production employees in the chemical industry manufacture products ranging from car paint to pharmaceuticals. This includes mixing chemical components, which then produce the desired properties in the end product.

It is important that the work is carried out flawlessly. The desired properties can only be achieved if the components are mixed very precisely. This is why special production systems are used, but it is important to set them up correctly.

During production, the employees constantly check the measuring instruments. This allows them to track which substances are being processed, in what quantities, at what temperatures, with what moisture content, and in what way. This means they can see exactly what is happening at all times and whether the specifications are being adhered to. If there are any deviations, they intervene and make adjustments.

What are the future prospects of working as a production employee in the chemical industry?

Working as a production employee in the industry is stable, with strong prospects for the future. The demand for products is constantly increasing, which means that employment opportunities will be maintained in the long term, and the number of jobs is likely to grow.

Work on the products begins in the development laboratory. Here, employees work on finding new compounds to achieve the desired properties in the substances. Once this has been achieved, the work continues in order to simplify the processes and make them more cost-effective. In this area, the work includes the precise weighing of ingredients and mixing according to specific formulas.

Production then involves manufacturing the desired materials in large quantities. To ensure that this is done precisely, machines are used. This means that employees are responsible for operating these machines, maintaining them, and keeping them in good working order.

What knowledge is required to work with machines?

Production employees need technical knowledge to work with machines. This enables them to understand how detergents, fertilizers, dyes, and other substances function and how to correctly apply or produce these effects. They carry out regular checks, clean the machines, and perform minor repairs, such as replacing worn parts. The priority here is to ensure a consistent standard.

Quality assurance takes place alongside the various production steps. For this purpose, the mixing ratios of the substances, the temperatures in the systems, and the pressure levels are constantly monitored. Samples are taken to check the acid content and viscosity. If the values do not match the specifications, the systems are readjusted accordingly.

All work steps and all results of the checks and tests are recorded in detail. In addition, information on the adjustments made during ongoing production is documented. This also includes the original settings and any readjustments to the equipment.

The documentation makes it possible to seamlessly trace which properties were present in the substances at each step. It is also possible to determine what led to deviations or what resulted in the desired outcomes. This makes processes repeatable in the future or allows necessary readjustments to be avoided by selecting the correct settings from the outset.

After the work is completed, the production waste is disposed of. This is done in an environmentally friendly manner and in accordance with relevant regulations to prevent any danger to people and the environment.

What jobs are open to production employees from the chemical industry?

Work in the chemical industry is very diverse. It is therefore important from the outset that companies looking for new employees describe job roles in sufficient detail. Conversely, applicants are required to read job advertisements carefully in order to decide on the right position.

The various employment sectors often focus on a specific range of products. For example, there is a separate area for the pharmaceutical industry, which we will look at in more detail later. Other areas include cleaning agents, paints, and plastics, the latter often used for the production of containers and packaging. There is also the area of food additives, such as preservatives, as well as the production of personal care products and cosmetics.

In addition to laboratories, typical workplaces include production halls, storage areas, and control rooms. However, this does not mean that remote work is an option here, teams usually work in close collaboration with laboratory staff and therefore also in close physical proximity to them.

What are the working hours like in the chemical industry?

Working hours in the chemical industry are generally flexible. There are early, late, and night shifts. In larger companies, production often runs continuously. This includes weekend and public holiday shifts in order to prevent production delays. This is especially important in the medical sector.

This means employees must adapt to these conditions. Additionally, peak order periods are common and may require overtime. For example, if a large order for cleaning agents comes in, everyone must pitch in and be ready to work longer hours.

While this time commitment can't always be planned or predicted, there is a benefit: work on public holidays, weekends, at night, and overtime is paid at a higher rate. Some companies also offer the possibility to work part-time alongside a full-time position, depending on internal policy.

What does a production employee in the chemical industry earn?

A production specialist working a 40-hour week in Germany earns an average gross salary of €4,750 per month. However, the actual salary depends on several factors in each individual case.

For example, there are regional differences in pay. The cost of living is generally higher in southern Germany. As a result, salaries in those regions tend to be higher than those in northern Germany. Salaries in eastern Germany also remain lower than those in the west.

Other influencing factors include training and professional experience. The more additional training an employee has completed, and the more specialized their expertise in high-demand fields, the higher their potential salary. Salaries also increase with relevant work experience.

What qualifications and skills does a production employee in the chemical industry need?

Generally, no formal training is required to work as an assistant. However, if you want to become a production specialist, you should complete training in this field. The training lasts two years and follows a dual system, meaning it takes place both at a vocational school and in a company.

No specific school-leaving qualification is required, but most companies expect an intermediate level of education.

After successfully completing training as a chemical production specialist, various opportunities for further education and specialization are available. You can become an industrial foreman in chemistry or pharmacy, or train as a technician in chemical engineering or environmental protection technology. For those aiming higher, university studies in chemistry, biochemistry, or process engineering are possible.

In addition to formal qualifications, production specialists in the chemical industry should possess certain personal attributes. This includes a strong interest in chemistry and chemical processes, which forms the foundation for motivation and willingness to learn.

Technical understanding is also essential, as work in this field involves a great deal of interaction with technology, machinery, and systems. Excellent hand-eye coordination is important for performing precise tasks, for example, when taking samples for laboratory analysis.

Are AI skills important for working in the chemical industry?

Given today’s technological standards, good IT skills are increasingly important. Analysis and evaluation of data are performed on computers. In addition, employees must be familiar with laboratory software and the programs used to monitor and control production processes.

This is complemented by soft skills, which are vital in the chemical industry. Precision and attention to detail are crucial. Employees must follow instructions and formulas exactly, not approximately. This is the only way to meet strict quality standards.

Production employees must also respond quickly in the event of a problem. If a system malfunctions, immediate action must be taken to prevent accidents or contamination of large quantities of materials.

Problem-solving skills and the ability to make quick decisions are also necessary. These enable employees to take appropriate action to minimize delays and restart processes efficiently by adjusting machines as needed.

What tasks do production employees perform in filling and labeling in the chemical industry?

Production employees perform a range of tasks in filling and labeling. These include operating the relevant machines as well as managing storage and quality control of the filled products.

Machines are used for filling, and they must function correctly. This requires accurate settings and continuous monitoring. Production employees ensure that the machines dispense the correct amount in the right way.

Bottles, cans, barrels, and other containers must be prepared accordingly. While much of this process is automated, machines need to be loaded. Production employees prepare the process by correctly positioning containers in the machines and adding more as needed.

The filling of liquids and powders must be closely monitored. Employees check that the chemicals enter the containers properly and that the exact quantities are dispensed.

What do production employees do in quality control?

In quality control, employees take samples that are then analyzed in the laboratory. This ensures that products meet all relevant requirements, standards, and legal specifications.

After filling, the containers are either labeled directly or packaged first and then labeled. In either case, employees ensure that filling, sealing, packaging, and labeling are all carried out correctly. They are also responsible for proper storage of the finished products.

Documentation is created for all process steps, from order receipt to filling and quality testing. Employees record what happens, which standards were followed, and note any deviations.

Production employees are also involved in cleaning and maintenance. This includes ensuring that containers used for filling are not contaminated. They also clean work areas and assist with system maintenance.

What are the working conditions like in the chemical industry?

Working conditions in the chemical industry differ slightly from those in other sectors. A heightened awareness of safety is required, as the chemicals used often have properties that make handling them hazardous.

Filling processes take place in production halls using machines and automated systems. Nevertheless, employees must follow strict regulations and wear personal protective equipment. This includes gloves and safety goggles; in many cases, respiratory protection is also required.

As in many other industries, shift work is common. The specifics vary depending on the company and order volume, but employees must be flexible enough to adapt to the conditions.

How can production employees be deployed in storage and transportation in the chemical industry?

Production employees in the chemical industry are also involved in storing and transporting raw materials, intermediate products, and finished goods. This begins with incoming deliveries. As soon as materials arrive at the plant, production employees check whether they meet the required specifications and quality standards.

The materials are then stored in suitable, specially designated areas. Storage conditions and safety guidelines must be strictly followed, including specifications such as temperature, pressure, and humidity.

Production employees are also responsible for maintaining inventory lists. They ensure that the warehouse is well-organized so that materials can be retrieved promptly when needed.

In addition to storage and transportation production workers also prepare materials for production. They divide them into portions, pack them where necessary, and prepare them for transport within the company or to another location.

The packaging is marked with standardized labels for transport. This allows every package to be tracked and retrieved or opened as needed. Applicable safety guidelines and regulations are also followed to ensure secure transportation.

Within production halls, employees transport materials to the machines and systems where they will be processed. Tools like forklift trucks are used for this.

What tasks do production employees perform in logistics?

In logistics, production employees coordinate the storage of raw materials, manage inventory, and ensure transportation to the actual production site. This also includes collaboration with quality assurance.

They document how materials are stored and which transport processes they go through. This helps to optimize operations and enhance safety.

When hazardous chemicals are involved, safety regulations require special attention. Employees must wear protective gear and carry out tasks with extra care to prevent accidents. They analyze workflows to identify critical points and implement measures to reduce risks.

Automation is also gaining traction in logistics and warehousing. More automated systems and autonomous vehicles are being introduced. However, this doesn’t eliminate the need for production workers. On the contrary—they must set up, monitor, clean, and maintain these systems.

This ensures that production workers continue to play a vital role. Their skills and expertise make processes more efficient and safer.

What do production employees need to know about safety and occupational health in the chemical industry?

Occupational health and safety are major concerns in the chemical industry. In the past, serious incidents ranged from injuries involving hazardous substances to entire plant explosions. Fortunately, significant improvements have been made, leading to fewer accidents and less severe consequences.

However, the work is still far from risk-free. The hazards remain, but the approach to handling them has improved. Greater emphasis on safety has helped reduce risks, but workers must still act with caution and responsibility.

It's not just the large-scale accidents that matter. Small, everyday risks to health and safety must also be addressed. Companies are legally required to protect their employees, and workers are obligated to follow safety rules carefully.

Why are safety concepts in the chemical industry essential?

Unfortunately, it is a reality in the industry that smaller risks often cause the majority of reportable workplace accidents. It is therefore crucial to develop, optimize, and follow structured work concepts that take this into account. Employees must be aware of the risks, recognize potential sources of error, and manage threats effectively.

This also means that production employees receive regular safety training on risk factors and accident prevention. Often, it’s the small mistake, caused by carelessness or complacency, that lead to serious consequences.

It is equally important not to overlook less obvious dangers while focusing on well-known hazards. For instance, while corrosive substances can clearly damage health upon skin contact, an overly narrow focus on avoiding them may lead to accidents with machinery. Employees must understand the broader context of risk and how safety is maintained throughout operations.

Some dangers are nearly invisible to production workers. These include the inhalation of substances like solvents or paints. While not always immediately harmful, they can cause long-term damage, ranging from allergies to cancer.

How are hazards for production workers in the chemical industry recognized and assessed?

Before companies can begin to implement measures for safety and occupational health, they must first be aware of the hazards. For this purpose, a dedicated risk assessment is carried out. This means identifying and evaluating all potential hazards that exist in the company, in its processes, and in the handling of materials. This then forms the basis for a safety and health management system.

The risk assessment is required by law and anchored in the Occupational Health and Safety Act. In addition, there are EU directives and further regulations and laws that stipulate how companies must ensure safety.

One challenge in the risk assessment is evaluating human behavior. Accidents are often caused by human error. Frequently, there is a discrepancy between the behavior expected from employees and the behavior they actually exhibit. It is difficult to ensure that all employees truly understand all relevant rules and then actually follow them.

What measures prevent accidents during production in the chemical industry?

There are many different individual measures tailored to the specific conditions of each company to prevent accidents. Technology is often used as part of this effort.

When working with heavy machinery, there are often safety devices in place to prevent people from reaching into the machines or being pulled into them. For example, rollers and balers are equipped with personal protection systems that stop the machines as soon as a hazard is detected. In this case, technology serves as a complement to human behavior to protect employees.

In this context, it is important to understand that technology can only intervene to save lives if it is properly configured. To ensure this, machine procurement must comply with applicable standards and certifications.

In addition, there is increasing interaction between machinery and personal protective equipment. This equipment now includes more and more intelligent systems that interact with the machines' safety mechanisms. For example, a transponder can trigger the shutdown of a machine if the wearer comes too close to it.

How can human error be avoided in the chemical industry?

People often play a key role in workplace accidents, not just as victims, but frequently as the cause. It is usually individual mistakes, stemming from carelessness or lack of knowledge, that lead to most incidents. Therefore, employees must be informed about the safety regulations they are required to follow and the safety measures in place. In addition, they need to be made aware of the importance of handling these risks responsibly.

The best way to implement both is through training, instruction, and safety briefings. These sessions cover work processes, explain the associated risks, and outline the protective measures that can help prevent accidents. They also teach production employees how to respond appropriately in the event of a malfunction or emergency.

Employees must know what risks exist to their health and safety. They must also be able to comply with safety rules and act according to the relevant protective protocols. Training also includes instruction on safety systems, for example, how transponders can trigger a machine to shut down and what steps to follow afterward. They must also be able to check independently whether they are wearing the transponder and whether it is functioning correctly.

Technological progress has already made its mark on these training programs. They now combine in-person sessions with various e-learning modules. In addition, tests and learning segments with gamified elements are used to increase motivation and improve compliance with safety regulations.

What control mechanisms do companies use to ensure safety and occupational health for production workers in the chemical industry?

Not only production workers, but companies themselves are subject to strict regulations regarding workplace safety and health protection in the chemical industry. As a result, companies are required to implement specific control mechanisms to ensure the safety and protection of production employees.

This starts with the obligation to inspect work equipment. For this, companies must check the machines and systems before they are put into operation for the first time. Further inspections are required during ongoing use.

There are different deadlines for the individual inspections, which companies must comply with. These deadlines are based on the risk assessment. Machines and systems must also be checked whenever they have been exposed to an influence that could cause damage or lead to a dangerous situation.

Additional inspections must be carried out after every accident or when a change has been made to the machine or system. If there was a longer period of non-use of the systems or a natural event occurred, an inspection must also be carried out.

There are three types of inspections, with either all three or a specific type used depending on the situation. The first type is the visual inspection. This is simple and relatively quick to carry out and should therefore take place before each individual use.

The second type is the function inspection. This ensures that all components of the systems carry out their own work steps correctly. The third type is the technical inspection, which involves measuring certain values.

The inspections are documented, and in this context, the inspectors also record whether there are any deviations and what kind they are. If employees initiate measures to readjust the systems, they also record this.

What are the working conditions like for production employees in the chemical industry?

In the chemical industry, there are working conditions that are known to be demanding. This involves expertise, a good sense of responsibility, and a lot of safety. But it also means that there are good collective agreements. This connects the potentially dangerous environment with good pay.

In fact, 78 % of employees in the chemical industry are covered by collective agreements. This is a top value compared to other industries. In addition, the annual gross salaries average 77,000 euros, clearly exceeding many other industries.

Qualified jobs and attractive challenges also make working in this field interesting. But it also means that for a good income, solid specialist knowledge and a strong sense of responsibility are required.

Jobs in the chemical industry are stable. But it also means that for a good income, solid specialist knowledge and a strong sense of responsibility are required.

On the other hand, work in the chemical industry involves handling chemicals. These are often dangerous, so production employees must follow strict safety regulations and wear protective clothing at work.

In addition, the working environment itself is demanding. Not only are dangerous processes constantly taking place there, these are also often connected with heat, noise, and other negative side effects. This does not always make the work pleasant.

Conclusion

The areas of deployment for production employees in the chemical industry are similar in some aspects to those of other industries, but they often go clearly beyond that. They range from equipping the machines, their operation, cleaning, and maintenance, to filling, packaging, and shipping, all the way to quality assurance. In addition, there is clearly more work in the laboratory as well as the strict following of formulas when mixing materials and during production processes. Here, the work is connected with a special level of responsibility and care.

For working in the chemical industry, a completed vocational training and further training, as well as specializations, are often required. However, these also have a positive effect on the pay. This is generally higher than in other industries, so for many, employment in the chemical industry is worthwhile.

In filling and labeling, the production employees ensure that the correct products are filled into the correct containers made of the correct materials, in the correct quantity and the correct quality. This often happens by machine, so the production employees are responsible for setting up, monitoring, readjusting, maintaining, and cleaning the machines. They also ensure that the products in the containers match the labeling.

A major topic in the chemical industry is safety and occupational health protection, since dangerous substances and machines are often used here. For this, technical means are used, such as transponders that automatically shut down machines when employees get too close to them. In addition, there are trainings to instruct and raise awareness among the employees. Companies also use various control mechanisms to ensure safe work on the machines.

The working conditions in the chemical industry are overall demanding. In contrast, however, there are varied tasks and above-average pay. Moreover, jobs of this kind are considered secure and offer good future prospects.