Senior Control Systems Engineer

Key Responsibilities

Controls System Design & Development

• Design complete control systems for industrial processing equipment and integrated production systems.
• Develop PLC, HMI, and SCADA applications to support machine operation, process control, recipe management, and data collection.
• Create functional specifications, control narratives, and machine operating sequences.
• Develop and maintain control system standards that promote consistency, scalability, and maintainability.
• Evaluate and implement emerging automation technologies to improve machine performance and customer value.
• Work with customers to develop specifications and expectations.

Electrical & Controls Engineering

• Develop:
• I/O lists
• Electrical schematics
• Network architecture drawings
• Control panel layouts
• Instrumentation specifications
• Alarm and fault management strategies
• Specify and integrate instrumentation, drives, motors, sensors, load cells, safety devices, and process equipment.
• Support panel design and review electrical drawings for compliance with applicable codes and standards.

Programming & Integration

• Program and troubleshoot PLC-based control systems.
• Develop HMI interfaces that provide intuitive operator interaction and system diagnostics.
• Configure industrial communications networks and integrate third-party equipment.
• Support database connectivity, reporting systems, and production data acquisition where required.
• Collaborate with OEM suppliers and customers during integration activities.

Project Execution

• Participate in project planning, budgeting, scheduling, and execution.
• Coordinate controls-related activities with internal teams, vendors, and customers.
• Support procurement and technical review of automation hardware and software.
• Ensure controls deliverables are completed on schedule and within project requirements.

Testing & Commissioning

• Develop and execute Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT).
• Lead machine startup and commissioning activities at customer facilities.
• Perform troubleshooting, loop checks, functional testing, and system validation.
• Provide operator and maintenance training following installation.

Customer Support & Continuous Improvement

• Assist customers with troubleshooting, upgrades, and system improvements.
• Support retrofit and modernization projects for existing GEMCO equipment.
• Document lessons learned and incorporate improvements into future designs.
• Help develop standardized automation platforms across product lines.

Safety & Compliance

• Design systems that comply with applicable electrical, machine safety, and industry standards.
• Participate in machine risk assessments and safety system reviews.
• Support implementation of safe machine operation and maintenance practices.

Required Qualifications

Education

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related engineering discipline.

Experience

• 5+ years of experience in industrial automation, controls engineering, machine design, or manufacturing systems.
• Experience supporting custom machinery, OEM equipment, or process manufacturing environments.
• Proven experience managing projects from design through commissioning.

Technical Skills

• Strong experience with:
• Allen-Bradley ControlLogix and CompactLogix platforms
• Siemens PLC platforms
• FactoryTalk View, WinCC, Ignition, or comparable HMI software
• Knowledge of industrial communication protocols including:
• Ethernet/IP
• Profinet
• Modbus TCP/RTU
• OPC-UA
• Experience with:
• Variable frequency drives (VFDs)
• Motion control systems
• Industrial instrumentation
• Safety circuits and machine safeguarding
• Familiarity with SQL databases and industrial data collection systems.
• Ability to read and create electrical schematics and control documentation.

Professional Skills

• Strong analytical and troubleshooting abilities.
• Excellent written and verbal communication skills.
• Ability to manage multiple projects simultaneously.
• Customer-focused mindset with strong interpersonal skills.

Preferred Qualifications

• Experience with powder processing, blending, drying, pharmaceutical, food, or chemical manufacturing equipment.
• Knowledge of batch process control systems.
• Familiarity with UL 508A panel design requirements.
• Experience with validation protocols including FAT, SAT, IQ, and OQ documentation.
• Exposure to Industry 4.0 technologies, remote diagnostics, and predictive maintenance systems.

Travel Requirements

• Ability to travel approximately 40–50% for customer meetings, equipment startup, commissioning, and service support.

Pay: $110,000.00 - $140,000.00 per year

Benefits:

• 401(k)
• Dental insurance
• Health insurance
• Life insurance
• Paid time off
• Vision insurance

Work Location: In person