Fermenter operator

Fermenter operators control and maintain the equipment and tanks for the production of active and functional ingredients for pharmaceuticals such as antibiotics or vitamins. They also work in the production of cosmetics or personal care products.

A fermenter operator typically does the following:

• Pumps specified number of gallons of cooked mash and yeast into fermentation tank, simultaneously, to ensure that mash and yeast are thoroughly mixed together.
• Opens valves to admit specified number of gallons of water into mixture, according to formula.
• Opens valves to circulate steam through coil pipes in tank to heat mixture to prescribed temperature.
• Turns valves to admit and control air pressure that agitates mixture as it ferments or to accelerate chemical reaction of yeast.
• Observes gauges or dials to ascertain that prescribed temperature and gas pressure are remaining constant in tank.
• Tests mash at prescribed intervals to determine temperature and specific gravity (proof), using thermometer and alcohol-proof hydrometer.
• Compares test results with standard charts to determine when mixture is fully cooked.
• Regulates steam, air, and gas pressure in tank to ensure that chemical reaction of yeast and fermentation process is taking place, according to formula.
• Pumps sour mash into cistern tank, preparatory to distilling.
• Cleans tanks by rinsing them with water.

The following job titles also refer to fermenter operator:

chemicals fermenter operative
chemicals fermenter operator
fermenter operative
fermentation worker
fermentation operative
fermentation process worker
chemicals fermentation operative
chemicals fermentation process worker
chemicals fermentation worker
fermenter worker
chemicals fermenter worker
chemical fermentation process worker
pharmaceutical fermenter operator

A high school diploma is usually the minimum required to work as a fermenter operator.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Fermenter operator is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to fermenter operator.

wine fermenter
nitrator operator
paint mixer
pesticide mixer
clay products dry kiln operator

These occupations require some skills and knowledge of fermenter operator. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of fermenter operator with a significant experience and/or extensive training.

chemical plant control room operator
chemical processing plant controller
chemical manufacturing quality technician
gas processing plant supervisor
occupational health and safety inspector

This knowledge should be acquired through learning to fulfill the role of fermenter operator.

• Good manufacturing practices: Regulatory requirements and Good Manufacturing Practices (GMP) applied in the relevant manufacturing sector.
• Lab scale fermentation: The steps and requirements included in lab scale fermentation for the conversion of the biomass into chemicals, sugars or fuels.
• Production scale fermentation: Large-scale fermentation used for ethanol production which is further used in productions such as food, pharmaceuticals, alcohol or gasoline production.

These skills are necessary for the role of fermenter operator.

• Ensure compliance with environmental legislation: Monitor activities and perform tasks ensuring compliance with standards involving environmental protection and sustainability, and amend activities in the case of changes in environmental legislation. Ensure that the processes are compliant with environment regulations and best practices.
• Measure density of liquids: Measuring the density of liquids, including oils, using instruments such as hygrometers, or oscillating tubes.
• Ensure compliance with safety legislation: Implement safety programmes to comply with national laws and legislation. Ensure that equipment and processes are compliant with safety regulations.
• Monitor environmental parameters: Check the impact of manufacturing machinery on the environment, analysing temperature levels, water quality and air pollution.
• Adhere to standard procedures: Adhere to and follow the Standard Operating Procedures (SOP).
• Manage bioreactors: Manage the bioreactors used in the fermentation process and cell culture, by setting them up, operate them and perform minor maintenance operations.
• Adjust fermentation processes: Perform the scaling-up or scaling-down of the fermentation processes according to the situation.
• Write batch record documentation: Write reports on the manufactured batches history taking into account the raw data, tests performed and compliance to Good Manufacturing Practices (GMP) of each batch of product.
• Monitor fermentation: Supervise and control fermentation. Monitor the settling of juice and the fermentation of raw material. Control the progress of the fermentation process to meet specifications. Measure, test and interpret fermentation process and quality data according to specification.

This knowledge is sometimes, but not always, required for the role of fermenter operator. However, mastering this knowledge allows you to have more opportunities for career development.

• Biotechnology: The technology that uses, modifies or harnesses biological systems, organisms and cellular components to develop new technologies and products for specific uses.
• Pathogenic microorganisms: The main classes of pathogenic microorganisms, the spread of infection and the use of universal precautions.
• Fermentation processes of food: Conversion of carbohydrates into alcohol and carbon dioxide. This process happens using bacteria or yeasts, or a combination of the two under anaerobic conditions. Food fermentation is also involved in the process of leavening bread and the process of producing lactic acid in foods such as dry sausages, sauerkraut, yogurt, pickles, and kimchi.
• Fermentation processes of beverages: Fermentation processes related to the conversion of sugar to alcohol, gases and acids. 

These skills and competences are sometimes, but not always, required for the role of fermenter operator. However, mastering these skills and competences allows you to have more opportunities for career development.

• Keep inventory of goods in production: Keep inventory of goods whether they are goods in the front end (i.e. raw materials), intermediate, or back end (i.e. finished products). Count goods and store them for the following production and distribution activities.
• Detect microorganisms: Use various laboratory methods and tools such as gene amplification and sequencing to detect and identify microorganisms such as bacteria and fungi in soil, air, and water samples.

8131 – Chemical products plant and machine operators

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References

1. ESCO
2. Fermentation Operator: A description for the fermentation operator job – Job Descriptions