Process Industry Manufacturing Technician Apprenticeship (ST1407)
This apprenticeship prepares technicians to operate, monitor and maintain complex process manufacturing systems within high-hazard industrial environments such as chemicals, petrochemicals, energy, hydrogen production, polymer production, green fuel production and large-scale continuous processing plants.
Level 3
Duration36 months to gateway (EPA Period: 3 months)
Programme Overview
This apprenticeship prepares technicians to operate, monitor and maintain complex process manufacturing systems within high-hazard industrial environments such as chemicals, petrochemicals, energy, hydrogen production, polymer production, green fuel production and large-scale continuous processing plants.
Technicians run processes safely and efficiently, support quality control, maintain plant performance, and ensure strict compliance with health, safety and environmental regulations. The role involves working within highly controlled environments using high-hazard substances and sophisticated production technology.
This programme builds fully competent process technicians able to work confidently with minimal supervision.
Who This Programme Is For
- Individuals starting or progressing within chemical, petrochemical, energy, hydrogen, polymer or other process industries
- Employers needing highly competent technicians able to operate complex, high-hazard processes
- Early-career process operators ready to develop advanced operational and plant skills
- Organisations that run 24/7 continuous production environmentsand need reliable, disciplined operators
- Apprentices who enjoy technical work, safety-critical environments and detailed processes
What Apprentices Will Learn
Process Operations & Control
- Operating and monitoring continuous process systems
- Adjusting process parameters to maintain product quality
- Starting up, shutting down and stabilising plant equipment
- Working within strict operational envelopes and safety constraints
Health, Safety & Environmental Management
- Working within COMAH-style safety environments (high hazard)
- Using PPE such as chemical-resistant gloves, suits, breathing apparatus
- Following operational safety systems, risk assessments and permits
- Environmental protections and waste/chemical handling
Quality Assurance & Process Integrity
- Conducting quality checks and verifying product specifications
- Identifying deviations, resolving issues or escalating appropriately
- Recording accurate process data and performance information
- Following manufacturing regulations and site quality systems
Plant & Equipment Support
- Preparing equipment for maintenance
- Supporting inspections, isolations and lock-out/tag-out systems
- Bringing equipment back online safely after maintenance
- Understanding plant diagrams, flows, systems and controls
Teamworking & Multi-Disciplinary Coordination
- Working with laboratory teams, maintenance, engineering, supply chain and warehouse
- Communicating process status and escalating abnormalities
- Collaborating with external stakeholders such as regulators, service providers and customers
Professionalism & Responsibility
- Managing own workload with minimal supervision
- Maintaining safety, accuracy and product integrity
- Demonstrating reliability, discipline and process ownership
Key Skills Developed
- Safe operation in high-hazard industrial environments
- Process control, monitoring and adjustment
- Incident response and escalation
- Quality assurance and compliance
- Technical problem-solving and diagnostic thinking
- Strong communication across multi-disciplinary teams
- Accurate documentation, reporting and shift handovers
End-Point Assessment (EPA)
Gateway Requirements:
- English & Maths at the required level
- Completed portfolio of evidence
- Employer confirmation of readiness
EPA Components:
- Observation with Questions
- Minimum of 3 hours
- Independent assessor observes real work activities
- Minimum of 5 follow-up questions
- Interview Underpinned by Portfolio
- Minimum of 60 minutes
- Minimum of 8 structured questions
- Portfolio used to support answers
- Multiple-Choice Knowledge Test
- 40 questions
- 60 minutes
- Use of a scientific calculator permitted
EPA Grading:
- Fail
- Pass
- Merit
- Distinction
Entry Requirements
- Employed in a suitable process manufacturing environment
- Ability to work safely and follow strict operating procedures
- Interest in technical, safety-critical and regulated environments
- Basic English & Maths (or willingness to achieve the required level)
- Employer able to provide structured, supervised process experience
Career Progression
Typical job titles include:
- Process Technician
- Chemical Process Technician
- Production Technician
- Hydrogen Production Technician
- Petrochemical Technician
- Oil & Gas Process Technician
- Plant Technician
- Process Manufacturing Technician
Progression opportunities include:
- Process Leader
- Science Industry Process and Plant Engineer (Degree Apprenticeship)
- Shift Lead, Control Room Operator or Senior Technician
- EngTech registration via IChemE (shortened route available)
Funding Information (Standardised ESTAR Format)
Funding Band
This apprenticeship is funded up to the maximum band set by the Department for Education: £24,000.
Funding Information
- Levy-paying employers:The full cost can be funded through your apprenticeship levy.
- Non-levy employers:You contribute 5%Â of the training cost, and the government funds 95%.
- Small businesses (under 50 employees):If the apprentice is 16–21, the government funds 100% of the training cost with £0 employer contribution.
- Additional supportmay be available for apprentices with learning difficulties or care-leaver status.
- There are no hidden costs.
Delivery Model (ESTAR Approach)
- Blended learningcombining theory, onsite workplace experience and practical assignments
- Regular coaching from an ESTAR industry specialist
- Structured portfolio developmentcovering full KSB evidence
- Monthly progress reviews with employer and apprentice
- Real-work process tasks aligned to the employer’s plant operations
- Full preparation for EPA including mock interviews, knowledge tests and scenario practice
- Typical timeline: 36 monthslearning + 3-month EPA window