Reactor Operator

Position Summary

The Reactor Operator is responsible for safely manufacturing liquid soap and personal care products by accurately blending raw materials according to approved formulas and batch records. This position operates reactors, mixing vessels, pumps, and associated processing equipment while ensuring compliance with Good Manufacturing Practices (GMP), quality standards, food-safe manufacturing requirements, and all safety regulations.

The Reactor Operator monitors the entire production process-from raw material staging through batch completion-to ensure products meet quality specifications, production schedules, and customer requirements.

Essential Duties and Responsibilities

• Safely manufacture liquid products according to approved batch records, formulas, and standard operating procedures (SOPs).
• Review production schedules, batch tickets, and formulas prior to beginning each production run.
• Verify that all raw materials have Quality Control approval before use.
• Accurately weigh, measure, and add raw materials in the required sequence.
• Operate reactors, mixing tanks, shear pumps, agitators, transfer pumps, and supporting process equipment.
• Monitor mixing parameters including temperature, mixing time, viscosity, agitation speed, and product appearance throughout the batch process.
• Record production data accurately, including ingredient usage, batch adjustments, deviations, overages, and substitutions with appropriate approvals.
• Transport raw materials using forklifts and pallet jacks while following safe material handling procedures.
• Identify material shortages and communicate inventory needs to Warehouse and Production leadership.
• Transfer finished batches to filling operations or designated holding tanks.
• Package and label finished bulk products in accordance with production and quality requirements.
• Perform routine equipment inspections and basic preventative maintenance.
• Clean, sanitize, and inspect reactors, tanks, pumps, hoses, pipelines, valves, utensils, and processing equipment between production runs.
• Complete production documentation accurately and in real time.
• Perform line clearance and verify equipment readiness prior to production.
• Maintain inventory of production supplies and properly identify raw materials and work-in-process inventory.
• Follow established waste reduction and material handling procedures.
• Maintain a clean, organized work area using 5S and Good Manufacturing Practices.
• Assist with troubleshooting equipment or process issues and report abnormalities promptly.
• Train and mentor new Reactor Operators as assigned.
• Support continuous improvement initiatives to improve safety, quality, efficiency, and productivity.
• Perform other duties as assigned.

Required Knowledge, Skills, and Abilities

• Understanding of Good Manufacturing Practices (GMP).
• Knowledge of safe chemical handling procedures.
• Ability to accurately follow batch records and manufacturing instructions.
• Mechanical aptitude with the ability to operate and troubleshoot manufacturing equipment.
• Ability to read scales and measuring devices accurately.
• Basic math skills for weighing, measuring, and calculating ingredient quantities.
• Ability to identify quality issues during the manufacturing process.
• Strong attention to detail and documentation accuracy.
• Ability to work independently and within a team environment.
• Effective verbal and written communication skills.
• Ability to prioritize multiple production tasks in a fast-paced manufacturing environment.

Qualifications

Required

• High school diploma or GED.
• One year of manufacturing experience in a process manufacturing environment.
• Experience operating industrial mixing, blending, compounding, or reactor equipment preferred.
• Forklift certification or ability to become certified.
• Basic computer skills for production documentation.

Preferred

• Experience in personal care, cosmetics, food, pharmaceutical, chemical, or soap manufacturing.
• Experience working in a GMP-regulated manufacturing environment.
• Experience with batch processing systems or ERP manufacturing software.

Equipment Operated

• Industrial reactors
• Mixing tanks
• Agitators
• Shear pumps
• Transfer pumps
• Piping systems
• Scales
• Forklifts
• Electric pallet jacks
• Drum handling equipment
• Pre-weigh stations
• Hand tools and cleaning equipment

Physical Requirements

• Stand and walk for up to 12-hour shifts.
• Frequently bend, stoop, reach, climb stairs, and kneel.
• Frequently lift up to 35 pounds.
• Occasionally lift up to 50 pounds with or without assistance.
• Push, pull, and maneuver drums, hoses, and production equipment.
• Wear required Personal Protective Equipment (PPE) including safety glasses, gloves, hearing protection, respirators (when required), and protective footwear.

Work Environment

The work is performed in an industrial manufacturing environment with exposure to:

• Liquid chemicals
• Fragrances and essential oils
• Elevated temperatures
• Noise from processing equipment
• Wet floors
• Moving mechanical equipment
• Powered industrial vehicles

Employees are required to comply with all safety policies, GMP requirements, Lockout/Tagout (LOTO) procedures, Hazard Communication (HazCom), and company operating procedures.

Success Factors

Successful Reactor Operators consistently demonstrate:

• Commitment to safety
• Attention to detail
• Quality-focused decision making
• Accountability and ownership
• Reliability and attendance
• Teamwork and collaboration
• Continuous improvement mindset
• Strong organizational skills
• Ability to adapt to changing production priorities