Senior Controls Engineer

The Senior Controls Engineer is responsible for the design, development, implementation, and maintenance of automation and control systems that support reliable, safe, and efficient operations within a food manufacturing plant. This role integrates electrical, mechanical, and software engineering disciplines to improve manufacturing processes and drive continuous improvement.

You will work cross-functionally with Maintenance, Production, Quality, and external vendors to deliver robust control solutions and support daily plant operations.

Key Responsibilities

Design & Implementation

• Design, program, and troubleshoot PLCs, HMIs, SCADA, and other automation systems (e.g., Allen-Bradley, Rockwell).

• Create and maintain electrical schematics, control panel layouts, and wiring diagrams.

• Select and integrate sensors, instrumentation, and industrial control hardware.

Process Optimization

• Analyze production processes to identify automation opportunities that improve throughput, reduce downtime, and enhance product quality.

• Develop and implement control strategies and continuous improvement initiatives.

• Conduct root cause analysis and corrective action for control system failures.

Technical Support & Maintenance

• Provide hands-on troubleshooting support to maintenance and production teams.

• Develop preventative maintenance plans for control systems and instrumentation.

• Ensure control systems meet safety and regulatory standards (e.g., OSHA, NFPA, NEC).

Project Management

• Lead automation and controls projects from concept through commissioning, including budgeting, timelines, and stakeholder coordination.

• Collaborate with contractors and suppliers on hardware/software specifications and installations.

Documentation & Training

• Maintain accurate documentation of system designs, configurations, and changes.

• Develop and update Standard Operating Procedures (SOPs) for control systems.

• Train operations and maintenance personnel on system usage and troubleshooting.

Compliance & Risk

• Ensure all controls work complies with relevant codes, standards, and food safety regulations.

• Participate in risk assessments, safety audits, and process hazard analyses as required.

Qualifications

Required

• Bachelor’s degree in Electrical Engineering, Control Systems, or related discipline—or equivalent experience.

• Minimum 5 years of hands-on experience with control systems in a manufacturing environment.

• Proficient in PLC programming (Ladder Logic, Structured Text, Function Block), HMI/SCADA development, and industrial networking protocols (Ethernet/IP, Modbus, Profibus).

• Strong knowledge of electrical systems, industrial instrumentation, and automation hardware.

• Proficient in reading and interpreting electrical schematics, P&IDs, and technical drawings.

• Excellent problem-solving, communication, and project management skills.

• Familiarity with safety and electrical codes (OSHA, NFPA 70E, NEC, IEEE).

Preferred

• Experience in food or beverage manufacturing environments.

• Working knowledge of Lean, Six Sigma, or TPM methodologies.

• Certification in Control Systems Engineering (CSE) or related credential.

• Hands-on experience with:

  • Hardware: Allen-Bradley (Stratix 5700, 1756/1734/5069 series, PowerFlex drives, PanelView), IFM (AL1123, AC1422), Endress+Hauser (CM444).

  • Instrumentation: E&H (Liquiphant, RTD, Promag, Mass Meter, Memosens), IFM (Flow, Pressure, Temperature, IO-Link), Emerson (Coriolis).

  • Software: RS Linx, FactoryTalk Suite (View, Linx, AssetCentre, Historian SE/OSI PI), ControlFlash+, ThinManager, PlantPAx 5.0, Active Directory, SQL, vSphere, Moneo, LR Device.

Physical Requirements

• Ability to stand, walk, and work in plant environments for extended periods.

• Ability to lift up to 50 pounds and handle tools, equipment, and materials as needed.

**Don’t meet every single requirement? Studies have shown that women and people of color are less likely to apply to jobs unless they meet every single qualification. At Meati™ we are dedicated to building a diverse, inclusive and authentic workplace, so if you’re excited about this role but your past experience doesn’t align perfectly with every qualification in the job description, we encourage you to apply anyway. You may be just the right candidate for this or other roles.**

Compensation:  
The base salary range for this role is $110,000 - $135,000 annually. Actual compensation may vary based on skills, experience, and location.