Process Engineering or Instrumentation and Automation?

[u/Financial_Snow_9041]

Hi all,

Currently working as a Process Tech. at a large pharmaceutical plant. Have held various process roles (process chemist, production chemist) and analytical roles (instrument chemist x2) across pharmaceutical, mining and geochemical industries the past 10 years. Have a level 8 (Hons) Marine Science degree, not really relevant to any of these industries but have satisfied other requirements when applying for previous roles so very lucky to have been offered them. To be brief, I'm working a rotating shift at my current job, although I do enjoy the job and the variety of tasks, I've found it's a very low-energy environment, sitting around in a control room some days for the majority of a 12 hour shift is driving me insane. I've learned shift jobs are not entirely suitable for high-energy or spirited individuals and some operators (more than some) just want to do minimal all the time. Also the night shift is beginning to take a mental and physical toll on mind and soul, if I am extremely disciplined (keto diet, exercise x2, reduced screen time, read books all the time etc. etc.) I can manage them but again I have to tightly control every other aspect of my life in order to overcome them and it takes a few days to recover and can be hard to keep a sense of humour.

I can't continue doing night shifts and I'm unsure what direction to take with my career but hoping to stay within the pharma / biopharma sector. I've accepted I'll have to return to study in some form and have been exploring all potential routes. I'm unsure whether to go down the Process Engineering route or go into instrumentation and automation, I feel I would enjoy the work of both.

Option 1: I'd considered returning to do a BSc (level 7) in Process Automation and Instrumentation at TUD, then do Year 4 of BSc (Hons) in Instrument Engineering at MTU which would open doors into instrumentation and automation. However I've heard mixed reviews on the course at TUD, so I've put this option on hold for the time being.

I've also looked at part time / online courses that would allow me to continue working and study at the same time. If this was the case the objective would be to jump back into a day shift QC / laboratory role for a few years while undertaking study in the evenings. Option 2: These pathways included doing a Cert. (level 6) in instrumentation and automation at ATU/MTU which would then allow entry in Mechatronic Engineering (4 years). Would this be a viable route into instrumentation and automation jobs? Would it be too difficult for someone like myself who doesn't have an electrical background? I'm fully aware that it'd be a dull and challenging few years, I'd have very little time to spare outside of work and study and no weekends. However, I'm very willing to put up with a few years of hardship if it means I'll get a decent paying job working normal day hours at the end of it.

Option 3: I've also looked at a Manufacturing Engineering at SETU (3 year cert then 2 year to get BEng). This course has elements of automation, PLC's and mechatronics and would open opportunities into process engineering or automation.

Sorry for the long-winded post. Ideally I'd love to continue working and study part-time but again, I'm unsure which direction to go. If anyone has any helpful advice or guidance or points they'd like to make that's relevant to anything I've mentioned above I'd love to hear them. Appreciate and very grateful for any input. Thanks.

 

[u/Strong_Guard3375]

Automation Engineer here. First off, I have witnessed people transfer from operator roles into automation on different sites without doing further education. Ask your employer if they could facilitate this.

I did an electronic and electrical engineering level 8 over ten years ago before getting into automation.

From my experience, Process engineers overlook the processes (obviously), they need to understand the equipment very well. They need to be able to know exactly how to define the requirements of the system such that automation can build what they want. This includes safety states, depending on where the batch is, different alarms should tigger different functionality etc... They analyse a lot of batch data and optimise the process to increase yield or improve safety. A lot of people I know who work in process generally have chemical/bioprocess/mechanical engineering degrees. I think of process guys as the real hands on the equipment.

In contrast, Automation engineers overlook the design, delivery and qualification of the automation software (obviously). A good automation engineer should understand network infrastructure and how networks communicate - from ethernet TCP to Profibus and everything in between, hardware such as SCADAs, PLCs or the components that make up a DCS (I/O and controllers etc...) so an understanding of basic electronics is quite important. Then of course they are generally quite skilled in developing the code, now the code isn't like developing apps for Microsoft, it is quite easy to pick up once you understand basic logic like if statements, loops and boolean logic. A lot of code can be generally quite easy to build out, but it does get quite complex for very complex processes. But this is all very learnable. Automation is a very much learn on the job career in my experience.

From my experience, Process are usually the guys at the skid, and very hands on with the equipment. Whereas automation will generally always be sitting down with a laptop in front of them. Instrumentation is usually a full career in itself which is very hands on and most people working in those roles are electricians, who would be very competent with wiring and loop drawings.

Suppose it comes down to what sounds more interesting to you? Do you like working with the equipment, or does the world of automation seem interesting to you? For me, automation can be very rewarding, especially at the end of a project and you get to see all the code you built just run the whole process. But it can be very stressful, it requires constant problem solving and learning, it can burn out the brain - which I personally need as I'm a bit wired naturally. On that note, automation engineers tend to be a bit neurodivergent!

Anyway, there's a long and winded ramble in response. Feel free to DM me if you've any questions.

Edit: I forgot to mention about the shift. I used to work shift and ended up quite depressed. It impacted my social life and I never felt like I could actually disconnect from work. So I understand what you mean. I no longer work shift, just days - around 40hours max per week and feel a lot better mentally.

[u/Financial_Snow_9041 → u/Strong_Guard3375]

Cheers pal, great insight, it's good to hear from someone who actually works in the space. I also know at least one operator that moved into automation from shift, however, he had a chemical engineering degree and they're in high demand.

I'm more drawn towards automation, could relate to that feeling of satisfaction you get after completing a project and seeing the results in motion.

Thanks again for the reply, I'll probably DM you with a few more q's as I think of them.

[u/Strong_Guard3375 → u/Financial_Snow_9041]

Hey my pleasure, bit of a ramble but feel free to send me any questions you have.

From my experience automation is very learable on the job and its all down to how interested you are in it. You start off with some basic tasks and before you know it, it becomes second nature. A couple of months working with a good team who are willing to show you stuff and you'll be flying.

I would usually recommend people start off with a system integrator like Emeron or Cognizant etc.. for the experience, but I think they're pretty tough on the education now. So definitely ask your employer if there is an opportunity. I've genuinely seen some people move from manufacturing to automation and being very successful.