Controls Engineer

SunOpta, Inc.; Allentown (Lehigh County); On-site; USD 90,000 - 120,000; Full time

Job summary

SunOpta, Inc. in Allentown, PA is seeking a Controls Engineer to design, implement, document, and support manufacturing automation and control systems across process, packaging, and utility operations.

You will work hands-on with Rockwell Automation platforms, develop FAT/SAT, ensure MOC/ACC, and uphold food safety, GMP, OSHA, NEC, and NFPA 70E standards while collaborating with Maintenance, Operations, Quality, Engineering, IT, and Corporate Engineering to improve reliability and efficiency.

Qualifications

• Bachelor's or Associate degree in Engineering, Engineering Technology, Industrial Automation, or related field or equivalent experience.
• 5+ years of applied industrial automation and controls in a manufacturing environment.
• Strong experience with Rockwell Automation platforms, including ControlLogix/CompactLogix PLCs, FactoryTalk View HMI/SCADA, and Studio 5000.
• Proven PLC programming, AOI development, commissioning, and troubleshooting experience.
• Experience integrating and supporting motor control systems, including VFDs and servo drives.
• Knowledge of electrical safety practices, OSHA and NFPA 70E compliance.

Responsibilities

• Design, program, test, document, and support PLC, HMI, and SCADA systems.
• Develop FAT and SAT for new or modified automation systems.
• Maintain control narratives, functional specs, PLC architectures, and AOIs.
• Implement advanced control strategies including PID, alarm management, and operator interface optimization.
• Collaborate with Maintenance, Operations, Quality, Engineering, IT, and Corporate Engineering to resolve issues.

Skills

Rockwell Automation

ControlLogix/CompactLogix PLCs

HMI/SCADA

Project collaboration

Safety compliance

Education

Bachelor's or Associate degree in Engineering

Tools

FactoryTalk View HMI/SCADA

Studio 5000

RSLogix 500/5000

EtherNet/IP networking

Job description

Job Summary:

• The Controls Engineer is responsible for the design, implementation, documentation, maintenance, and support of manufacturing automation and control systems across process, packaging, and utility operations.
• This role provides hands-on technical expertise in PLCs, HMI/SCADA systems, drives, instrumentation, and industrial networks to support safe, reliable, and compliant plant operations.
• The Controls Engineer supports capital projects, system upgrades, troubleshooting, and continuous improvement initiatives, working closely with Maintenance, Operations, Quality, Engineering, IT, and Corporate Engineering.
• This position serves as the plant technical authority for automation systems, ensuring alignment with company standards, Management of Change (MOC) requirements, Automation Change Control (ACC) practices, and cybersecurity expectations.
• The Controls Engineer is accountable for improving automation reliability, process control performance, and operational efficiency while maintaining compliance with food safety, GMP, OSHA, NEC, and NFPA 70E electrical safety standards.

Essential Functions of the Job:

Automation & Controls Engineering

• Develop, implement, and maintain standardized automation and electrical engineering practices.
• Design, program, test, document, and support PLC, HMI, and SCADA systems, with primary emphasis on Rockwell Automation / FactoryTalk, while supporting other industrial automation platforms as required.
• Configure, integrate, and support process control systems for process, utilities, and packaging operations.
• Develop and execute Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT) for new or modified automation systems.
• Develop and maintain control narratives, functional specifications, PLC control system architecture, and reusable PLC standards, including Add-On Instructions (AOIs).
• Implement and support advanced control strategies, including PID tuning, alarm management, and operator interface optimization.
• Develop, recommend, and implement automation and control improvements to enhance equipment performance, efficiency, and reliability.

Instrumentation, Drives & Networks

• Specify, integrate, and troubleshoot field instrumentation (pressure, temperature, flow, conductivity, pH, etc.) using best practices aligned with IEEE and IEC standards.
• Support calibration activities and coordinate with third-party calibration services in accordance with company standards.
• Integrate, configure, and tune VFD and servo motion systems, supporting reliable process control and equipment protection.
• Support and troubleshoot industrial control and PC-based networks, including EtherNet/IP, TCP/IP, and Modbus (legacy DeviceNet exposure a plus).

Reliability, Safety & Compliance

• Provide automation and controls expertise in support of maintenance and reliability programs, contributing to asset performance and lifecycle objectives.
• Ensure automation systems and work practices comply with OSHA, NEC, NFPA 70E, GMP, food safety, and company electrical safety standards.
• Participate in and enforce Management of Change (MOC) processes, including Automation Change Control (ACC) for PLC, HMI, SCADA, and control system modifications.
• Serve as a safety role model, promoting safe work practices and continuous improvement in electrical and automation safety.

Collaboration & Support

• Partner with Operations, Maintenance, Quality, Engineering, IT, and Corporate Engineering to resolve process, equipment, and system issues.
• Communicate automation system changes, capabilities, and impacts to affected stakeholders, and provide technical training and guidance to Control Technicians, Maintenance, and other technical services departments.
• Act as the plant-level technical escalation point for automation-related issues, with clear escalation paths to Corporate Engineering for complex or enterprise-impacting matters.
• Perform other related duties as assigned.

Minimum Qualifications:

• Bachelor's or Associate degree in Engineering, Engineering Technology, Industrial Automation, or a related field, or equivalent relevant experience.
• 5+ years of applied industrial automation and controls experience in a manufacturing environment.
• Strong experience with Rockwell Automation platforms, including ControlLogix / CompactLogix PLCs, FactoryTalk View HMI/SCADA, and Studio 5000 (legacy SLC500 / MicroLogix exposure a plus).
• Proven experience with PLC programming, Add-On Instruction (AOI) development, commissioning, and troubleshooting of manufacturing automation systems.
• Experience integrating and supporting motor control systems, including VFDs and servo drives.
• Demonstrated ability to troubleshoot automation systems from field instrumentation through control logic and operator interfaces.
• Experience in food, beverage, or aseptic manufacturing environments, including exposure to Tetra Pak processing or packaging equipment.
• Working knowledge of industrial electrical safety practices, including OSHA and NFPA 70E compliance.

Preferred Qualifications:

• Experience in aseptic, dairy, or high-speed beverage manufacturing environments.
• Familiarity with CIP systems, validation documentation, and regulated manufacturing requirements.
• Exposure to industrial networking and PC-based networking technologies.
• Experience supporting capital projects, equipment upgrades, and system migrations.
• Working knowledge of SQL Server or other relational databases in support of manufacturing systems.
• Knowledge of Lean / TPM manufacturing principles.
• Strong organizational, prioritization, and communication skills.
• Professional Engineer (PE) license or progress toward licensure.

Knowledge and Skills:

• Programming experience primarily with Allen Bradley ControlLogix, CompactLogix and SLC500 PLCs.
• HMI or SCADA programming and configuration.
• Allen Bradley PowerFlex VFDs.
• Knowledge of and familiarity with the National Electric Code (NEC) and international standards.
• Proficiency designing and programming control systems with emphasis on PLCs, HMI systems.
• Experience and demonstrated knowledge of thermodynamics and mechanics is required.
• Knowledge of Lean Manufacturing practices is beneficial.
• Strong verbal and written communication skills are required.
• Working knowledge of RSLogix 500,5000, and Studio 5000 Factory Talk view, and Studio.
• Basic network skills and troubleshooting.
• Must have a working knowledge of MS Word, Excel, and PowerPoint software.
• Prefer a candidate with SQF practical experience and training.
• Demonstrated results of solving complex technical issues.

Additional Considerations:

• Travel Requirements: Up to 10%.
• Location: This position will be at our SunOpta Plant in Allentown, PA.
• Personal Protective Equipment (PPE) is required when performing work in production or maintenance areas.