Controls Engineer - ZipRecruiter : Job Details

Job DescriptionJob Description

We're seeking a technically skilled Controls Engineer with PLC and HMI expertise to join a growing food & beverage manufacturing operation. In this role, you'll collaborate directly with Operations and Design Engineering teams to develop, enhance, and optimize control systems for Aseptic and Extended Shelf Life processes. Your precise technical work will be critical to ensuring product quality, food safety, and adherence to production specifications while solving complex challenges that directly impact manufacturing efficiency. If you're passionate about applying specialized knowledge of processing control systems to create measurable improvements in food & beverage manufacturing, this position offers the opportunity for hands-on problem-solving and technical growth.

Location: Greater Syracuse Area, NY

Job Responsibilities:

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

Required Skills/Qualifications:

• 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.
• PLC programming (Allen-Bradley, Siemens) with the ability to write and troubleshoot code.
• HMI design experience (AVEVA, FactoryTalk View) and familiarity with process databases (Historian).
• Proficiency in industrial networks (Ethernet/IP, DeviceNet, ControlNet).
• Ability to read and modify Process & Instrumentation Drawings (P&IDs).
• PID loop tuning and VFD setup experience (Allen-Bradley PowerFlex, Danfoss, Eaton).
• Expertise in digital and analog measurements (temperature, pressure, flow, speed, weight) and experience with discrete sensors.
• Strong organizational, teamwork, and communication abilities, with proficiency in Microsoft Office, AutoCAD, and reporting.
• Willingness to work flexible shifts as needed, including holidays, nights, and weekends.
• 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.
• Ability to navigate all areas of the facility, including office spaces, warehouse areas, and the exterior perimeter.
• Must wear required personal protective equipment (PPE) as necessary to safely perform job duties.
• Ability to stand, sit, and carry out tasks throughout a full shift, with appropriate meal breaks.
• Physically capable of standing, bending, stooping, kneeling, reaching, twisting, lifting, pushing, pulling, climbing, balancing, and crouching as needed.
• Able to lift and move items weighing up to 50 pounds independently and heavier objects with reasonable accommodations.
• Visual acuity sufficient to perform job duties accurately.
• Capable of assessing weights, judging distances, and working at various heights.