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Apprenticeship training course

Polymer processing technician (level 3)

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Information about Polymer processing technician (level 3)

Complete process manufacturing activities to produce polymer products to a specification.

Knowledge, skills and behaviours
View knowledge, skills and behaviours

Knowledge

  • Polymer industry awareness: range of polymer products, manufacturing environments, types of customers.
  • Polymer process technician’s role. Limits of responsibility. Escalation procedures.
  • 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.
  • 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.
  • 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.
  • Principles of sustainability and circular economy. Energy efficiency and reuse of polymers. Principles of control and management of emissions and waste.
  • Chemical terms associated with polymers: element, atomic mass, molecule, functional group, monomer, oligomer, polymer, polymerisation, molecular weight, molecular weight distribution, bonding, and tacticity.
  • Polymerisation processes: addition polymerisation, condensation polymerisation, catalyst, conditions. Sources of chemical materials; crude oil derived and bio-materials.
  • Thermal characteristics of polymers: glass transition temperature, melting temperature, processing temperature, specific heat, heat capacity, heat distortion temperature, melt density, thermal stability.
  • Classes of material: thermoplastics, thermosets, elastomers, rubbers, thermoplastic elastomers, commodity, engineering and high-performance materials, molecular structure, blends, and alloys.
  • Rheology behaviour: viscosity, shear stress, shear rate, newtonian flow, non-newtonian flow, viscosity-temperature relationships, flow measurement methods and indexes.
  • 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.
  • Influence of morphology on physical and mechanical properties of polymers.
  • Polymer materials: definition, classifications, properties, applications, products, and terminology.
  • Factors affecting the glass transition temperature of polymers.
  • Factors affecting the degree of crystallinity of polymers: molecular and processing.
  • Material data sheets, understanding test methods and data reported; physical, mechanical, thermal, optical, electrical, flammability properties of polymers.
  • 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.
  • The impact of re-used and re-cycled polymers on the processing conditions and final product properties.
  • 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.
  • 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.
  • Types of mould tools, formers and dies: purpose, features, construction, materials, damage and non-conformance checking requirements, and mounting methods (bolts, clamps, quick release).
  • 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.
  • Polymer processing material preparation requirements: formulations, drying, weighing, conveying, mixing, blending, and colouring of polymers.
  • Machine operating parameters: temperature, pressure, speed or timings, and distance. Impact of changes on the quality of the components. Adjustments required to resolve issues.
  • Polymer post processing techniques: assembling, printing, decorating, cooling operations, packing, and labelling.
  • Standard operating procedures: their purpose and why they are important, how they are developed and maintained.
  • Quality, cost, and delivery (QCD) standards and their importance in the workplace.
  • Quality assurance, testing, inspection, and sampling methods. Process and control systems.
  • Documentation requirements: documentation control, auditable records.
  • Purpose of audits and why they are important.
  • Preventative maintenance strategy and practice.
  • British standards for engineering representations, drawings, and graphical information.
  • Application of digital systems to support manufacture: CAD (computer-aided design), CAM (computer-aided manufacturing), CMM (coordinate measuring machine), and 3D printing.
  • Data analysis methods and techniques.
  • Problem solving and fault-finding techniques: root cause analysis, 5-Whys.
  • Continuous improvement (CI) methodologies and tools: lean, KAIZEN, 5S, workplace organisation.
  • 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.
  • Planning, prioritising, and time management techniques.
  • Principles of team working. Equality, diversity and inclusion.
  • Verbal communication techniques.
  • Written communication techniques. Report writing techniques.
  • Presentation techniques.

Skills

  • Review instructions or information. For example, work instructions, sampling requirements, drawings dimensioning, labelling, formulations, machine settings.
  • Plan task and identify and organise resources with consideration for safety, environmental impact, security, quality and cost.
  • Identify and document hazards and risks in the workplace.
  • Apply health, safety, and environmental procedures in compliance with regulations and standards. For example, daily machine checks, wearing personal protective equipment.
  • Apply sustainability principles for example, in choice of materials, minimising waste.
  • Segregate resources for reuse, recycling, and handling.
  • Select, check, and prepare materials for polymer processing for example, weighing, control and blending, and conditioning.
  • Select, configure (for example, replace or change inserts) and check mould tools, formers, dies or other process equipment.
  • Check installation and function of processing equipment for the process.
  • Connect service connections such as water, electrical, pneumatic, hydraulic.
  • Check hand tools, equipment and machinery including calibration record where applicable.
  • Set or check machine settings using instructions such as temperature, pressure, speed or time, distance.
  • Adjust machine setting for the speeds, positions, pressures and safety of the mould tool, former or die movement to meet product specification.
  • Start up manufacturing processes.
  • Monitor process feedback and adjust process parameters.
  • Shut down manufacturing processes.
  • Devise machine settings such as temperature, pressure, speed or time, distance for new or modified equipment, tooling or material.
  • Test and evaluate machine settings for new or modified equipment, tooling or material.
  • Select and apply optimal machine settings for new or modified equipment, tooling or material (for example, capability study).
  • Interpret data for example, process data, quality control and test procedure data. Use data to inform action.
  • Identify process faults and resolve.
  • Apply post processing techniques for example, assembly, printing, decorating, cooling operations, packing, and labelling.
  • Follow quality assurance processes during manufacture.
  • Perform quality control checks. For example, conduct parameter checks (size, colour, weight), and take samples.
  • Identify quality issues and resolve for example, defects, maintenance requirements.
  • Escalate issues outside limits of responsibility.
  • Apply preventative maintenance practices. For example, checking guarding, lubrication, cleaning of tooling, safety checks, and inspection for wear and tear.
  • 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.
  • Apply team working principles.
  • Communicate with others verbally for example, colleagues and stakeholders.
  • Record or enter information - paper based or electronic. For example, process and production records, traceability records, and quality assurance records.
  • Present information.
  • Communicate in written form in the workplace for example, handover notes or emails, non-conformances, design change requests, technical reports.
  • Use information and digital technology. Comply with GDPR and cyber security regulations and policies.
  • Plan how to meet personal development needs. Carry out and record planned and unplanned continued professional development (CPD) activities. Evaluate CPD against plans made.

Behaviours

  • Prioritise health, safety, and the environment.
  • Consider the environment and sustainability when using resources and carrying out processes.
  • Take responsibility for the quality of their own work.
  • Team-focus to meet work goals including a commitment to equality and diversity.
  • Respond and adapt to work demands.
  • Committed to continued professional development.
Apprenticeship category (sector)
Engineering and manufacturing
Qualification level
3
Equal to A level
Course duration
36 months
Maximum funding
£25,000
Maximum government funding for
apprenticeship training and assessment costs.
Job titles include
  • Injection moulding process technician
  • Injection moulding setter
  • Manufacturing technician
  • Process technician
  • Production technician
  • Polymer process setter
  • Polymer process technician
  • Polymer processing technician

View more information about Polymer processing technician (level 3) from the Institute for Apprenticeships and Technical Education.