We are partnering with a leading OEM specializing in custom automation and material handling systems used in highly regulated environments including pharmaceutical, food & beverage, and process manufacturing. This organization designs and builds engineered-to-order equipment and is seeking a Senior Controls Engineer / Electrical Engineer to support continued growth.
This role will focus on the design, programming, and commissioning of industrial control systems, supporting complex machinery from concept through installation and customer handoff.
Position Overview:
The Controls Engineer will be responsible for developing and implementing PLC-based automation systems, including electrical design, controls architecture, and machine integration. This is a hands-on engineering role requiring experience across the full lifecycle of industrial automation projects—from initial design and programming to FAT/SAT, commissioning, and field support.
Key Responsibilities:
- Design and develop industrial control systems, including electrical schematics, panel layouts, and wiring diagrams using AutoCAD Electrical or similar CAD platforms
- Program, troubleshoot, and optimize Allen-Bradley (Rockwell Automation) PLCs, including ladder logic development, HMI configuration, and VFD integration
- Lead controls engineering activities across multiple projects, supporting machine build, testing, and startup
- Execute Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT), ensuring system functionality and performance meet customer requirements
- Develop and maintain controls documentation, including functional specifications, I/O lists, and sequence of operations
- Collaborate cross-functionally with mechanical engineering, manufacturing, and project management teams to deliver fully integrated automation solutions
- Diagnose and resolve issues related to PLC programming, electrical systems, and industrial networks
- Support installation, commissioning, and occasional on-site troubleshooting at customer facilities
- Contribute to continuous improvement initiatives, including controls standardization and best practices
Qualifications:
- 5+ years of experience in industrial automation, controls engineering, or electrical engineering within a manufacturing or OEM environment
- Strong hands-on experience with Allen-Bradley PLCs (ControlLogix, CompactLogix, etc.), HMIs, and VFDs
- Proficiency in ladder logic programming and troubleshooting
- Experience with AutoCAD Electrical or similar CAD tools for control system design
- Demonstrated ability to manage projects from concept through commissioning
- Familiarity with industrial communication protocols such as EtherNet/IP, Modbus, or OPC is a plus
- Understanding of machine safety, electrical standards (UL, NFPA, CE), and industrial best practices is beneficial
- Bachelor’s degree in Electrical Engineering or related field preferred (equivalent experience considered)
Additional Details:
- Exposure to SCADA systems, data acquisition, or batch processing environments is advantageous
- Experience in regulated industries (pharmaceutical, food processing, or chemical manufacturing) is highly valued
- Ability to manage multiple projects in a fast-paced, custom engineering environment
- Willingness to travel occasionally for installation and support
This opportunity offers the chance to work on highly customized automation systems, leveraging modern PLC controls, HMI development, and electrical design in industries where precision, reliability, and compliance are critical.