Controls Engineer

Barry-Wehmiller; Bircotes; On-site; GBP 45,000 - 65,000; Full time

Job summary

BW Packaging (Barry-Wehmiller) seeks an Electrical Controls Engineer to design, develop, program, and support electrical control systems for automated packaging machinery and robotic systems. You will collaborate with mechanical, manufacturing, and service teams to deliver safe, reliable equipment that meets customer and regulatory requirements.

You will develop PLC/HMI programs, integrate robots from major platforms, optimize cycles, and maintain technical documentation.

Qualifications

• Bachelor's degree in Electrical Engineering or related field.
• Minimum 5 years of electrical controls design experience.
• Strong PLC programming experience (Rockwell/Allen-Bradley).
• Experience with HMI development and motion control systems.
• Programming experience with major robotic platforms (FANUC, ABB, KUKA, Yaskawa/Motoman).
• Experience integrating robots with PLCs, HMIs, motion systems, and vision inspection systems.
• Proficiency with electrical design tools (AutoCAD Electrical, EPLAN).
• Solid understanding of industrial networks and machine safety systems.
• Strong problem-solving and project management skills.

Responsibilities

• Develop and program PLC, HMI, motion control, and robotic systems for automated packaging lines.
• Program and configure industrial robots for applications such as pick-and-place, palletizing, case packing, and material handling.
• Integrate robots with PLCs, safety systems, vision systems, and peripheral equipment using industrial communication protocols.
• Configure and commission servo axes, sensors, vision systems, barcode scanners, printers, and inspection devices.
• Toubleshoot and resolve electrical, controls, and system issues during build, installation, and field support.

Skills

PLC programming

HMI development

Motion control

Robotics systems

Robot integration

Education

Bachelor’s degree in Electrical Engineering or related field

Automation/Controls background

Tools

AutoCAD Electrical

EPLAN

Job description

About Us:

BW Packaging is driving performance at the intersection of people, technology, and customer care. As part of the privately held Barry-Wehmiller family, we unite a global team of packaging experts with a clear purpose: People Who Care, Building Solutions that Perform. We take on our customers’ toughest challenges as our own — delivering both innovative and enduring solutions that set the standard for value and performance. Our strength comes from our people and the power of our brands — trusted names in packaging that are known worldwide for engineering excellence, application expertise, and lifetime commitment to customer success. Truly Human Leadership guides our belief that exceptional business results and profound respect for people together provide the foundation of enduring success. We are committed to forging lasting partnerships with our customers, earning their trust through integrity, expertise, and execution. With our full range of packaging solutions and long term partnership and service, we help customers achieve operational excellence today while building the future of packaging together.

Barry-Wehmiller is a diversified global supplier of engineering consulting and manufacturing technology for the packaging, corrugating, sheeting and paper-converting industries. By blending people-centric leadership with disciplined operational strategies and purpose-driven growth, Barry-Wehmiller has become a $3 billion organization with nearly 12,000 team members united by a common belief: to use the power of business to build a better world.

Job Description:

Job Summary

The Electrical Controls Engineer is responsible for the design, development, programming, and support of electrical control systems for automated packaging machinery, including integrated robotic systems. This role partners closely with mechanical engineering, manufacturing, and service teams to deliver safe, reliable, and high-performing equipment that meets customer and regulatory requirements. Success is measured by on-time, on- budget, quality equipment that meets performance expectations.

Key Responsibilities

• Develop and program PLC, HMI, motion control, and robotic systems for automated packaging lines.
• Program and configure industrial robots (e.g., FANUC, ABB, KUKA, Yaskawa/Motoman, or Universal Robots) for applications such as pick-and-place, palletizing, case packing, and material handling.
• Develop and optimize robot paths, end-of-arm tooling (EOAT) interfaces, payload configurations, and cycle time performance.
• Integrate robots with PLCs, safety systems, vision systems, and peripheral equipment using industrial communication protocols (EtherNet/IP, Profinet, etc.).
• Configure and commission servo axes, sensors, vision systems, barcode scanners, printers, and inspection devices.
• Configure and troubleshoot safety systems, including safe zones, guarding, light curtains, and safety-rated monitored stops.
• Support machine build, debug, and validation, including robot teach, calibration, and commissioning during FAT and SAT.
• Troubleshoot and resolve electrical, controls, and system issues during build, installation, and field support.
• Collaborate with cross-functional teams to ensure seamless integration of robotics into overall machine design and performance.
• Ensure compliance with applicable machine safety standards.
• Develop and maintain technical documentation, including electrical drawings, programs, backups, and operating manuals.
• Provide technical support to customers and field service teams, including on-site startup and optimization.
• May lead, guide, coach, or mentor less experienced team members; be a positive role model for the team.
• May develop schematics, panel layouts, and BOMs.
• Demonstrate flexibility and ability to work on other non-core product lines based on demand.
• Flexibility to take on evolving responsibilities in response to strategic priorities and business needs.
• Travel is an essential element to expand knowledge, support of our customers, and support business growth needs. Travel could be to company sponsored training, customers’ facilities, or other BW facilities both domestic and international. Estimated at up to 25% annually.

Qualifications & Desired Experience

• Bachelor’s degree in electrical engineering, Computer Science, Automation/Controls or a related technical field, from an accredited college or university equivalent combinations of formal education and relevant job experience may be considered.
• Minimum 5 years of electrical controls design and PLC/HMI development.
• Strong experience with PLC programming (Rockwell/Allen-Bradley preferred).
• Experience with HMI development and motion control systems.
• Programming experience with at least one major robotic platform (FANUC, ABB, KUKA, Yaskawa/Motoman).
• Experience integrating robots with PLCs, HMIs, motion systems, and vision inspection systems.
• Proficiency with electrical design tools (e.g., AutoCAD Electrical, EPLAN).
• Solid understanding of industrial networks and machine safety systems.
• Ability to troubleshoot complex electromechanical and robotic controls systems.
• Strong problem-solving, communication, and project management skills.

Physical Demands (Essential Functions)

• Ability to perform work in an engineering office and manufacturing environment.
• Ability to sit, stand, walk, and use hands to operate a computer and engineering tools.
• Ability to occasionally lift and/or move items up to 50 pounds.
• Ability to travel up to 25% domestically and/or internationally.
• Ability to work near moving mechanical parts and electrical systems in a safe manner, following all PPE and safety requirements.

At Barry-Wehmiller we recognize that people come with a wealth of experience and talent beyond just the technical requirements of a job. If your experience is close to what you see listed here, please still consider applying. We know that our differences often can bring about innovation, excellence and meaningful work—therefore, people from all backgrounds are encouraged to apply to our positions. Please let us know if you require reasonable accommodations during the interview process.

Company:

BW Packaging