Controls Engineer

Job Type

Full-time

Description

Position Title: Controls Engineer

Reports To: Technical Process Manager

FLSA Status: Exempt

Job Grade: 11

Pay Range: $114,000-$163,000

Local Candidates Preferred. Limited relocation assistance available

Previous Experience in Food Manufacturing required

Sponsorship is not available

Position Overview:

We are seeking a skilled Controls Engineer with extensive experience in PLC and HMI software within the dairy ingredients manufacturing industry. This role involves partnering closely with Operations and Design Engineering to enhance and develop Aseptic and Extended Shelf Life (ESL) processes. The Controls Engineer will play a critical role in ensuring product quality, food safety, and adherence to production specifications.

Job Responsibilities:

• Facility Startup Support: Lead the startup and commissioning of the new Aseptic ESL facility for Cayuga Milk Ingredients.
• Automation Design & Installation: Design and implement plant-wide automation systems, including PLCs and HMIs.
• System Monitoring & Maintenance: Oversee automated system performance, conduct regular maintenance, and troubleshoot issues to minimize downtime.
• Documentation Management: Record all modifications to equipment and systems, ensuring accurate and comprehensive documentation.
• Production Support: Respond to production issues promptly and provide technical support to resolve operational problems.
• MES/BMS Coordination: Assist with Manufacturing Execution System (MES) and Building Management System (BMS) activities and coordination.
• SOP Development: Aid in creating and updating Standard Operating Procedures (SOPs) for department processes.
• Automation Solutions Implementation: Introduce automation solutions to optimize operations and minimize manual intervention.
• Cross-Department Collaboration: Work closely with production, maintenance, supply chain, and accounting teams to integrate automation systems.
• Technical Documentation: Develop design specifications, user manuals, and troubleshooting guides for automated solutions.
• Compliance & Safety: Adhere to all environmental, GMP, HAACP, and OSHA regulations, ensuring a safe working environment and maintaining PPE standards.
• Technical Competency: Ensure processing equipment functions per SOPs and verify operational accuracy.
• Communication & Relationship Building: Communicate effectively, establishing strong working relationships across departments and providing clear, detailed reports to senior management.
• Independence & Task Management: Execute assigned projects independently and manage multiple tasks effectively.
• Availability: Occasionally work off-shift hours, including nights and weekends, to support 24/7 facility operations.

Essential Knowledge/Skills:

Technical Skills:

• PLC programming (Allen-Bradley, Siemens) with the ability to write and troubleshoot code.
• HMI design experience (AVEVA, Factory Talk View) and familiarity with process databases (Historian).
• Proficiency in industrial networks (Ethernet/IP, Device Net, Control Net).
• Ability to read and modify Process & Instrumentation Drawings (P&IDs).
• PID loop tuning and VFD setup experience (Allen-Bradley Power Flex, Danfoss, Eaton).
• Expertise in digital and analog measurements (temperature, pressure, flow, speed, weight) and experience with discrete sensors.

Organizational & Communication Skills:

Strong organizational, teamwork, and communication abilities, with proficiency in Microsoft Office, AutoCAD, and reporting.

Availability:

General 7am-4pm, Monday-Friday. Willingness to work flexible shifts as needed, including holidays, nights, and weekends.

Education/Experience:

Bachelor's degree in electrical engineering, Mechanical Engineering, or Computer Science.

Minimum 5 years as a Programmer/Controls Engineer in a manufacturing setting, preferably dairy or food production.

Environmental Considerations:

• Must be able to work in environments with varying temperatures.

• Potential exposure to ingredients used in food manufacturing, including allergens.

• May encounter chemicals commonly used in food processing and distribution facilities.

Physical Requirements:

• Ability to navigate all areas of the facility, including office spaces, warehouse…