Controls Engineer

W3Global; Middlesex (NJ); On-site; USD 130,000 - 170,000; Full time

Job summary

W3Global is seeking an experienced Controls Engineer to design, program, integrate, and commission automation systems for custom industrial equipment used in mixing, blending, drying, and material processing applications. This is a hands-on role spanning concept through startup, commissioning, and customer support.

You will lead control system design, PLC/SCADA programming, FAT/SAT, and field commissioning, collaborating with engineering, manufacturing, vendors, and customers.

Qualifications

• Bachelor’s degree in Electrical/Controls/Automation/Mechatronics or related field.
• 10+ years in industrial automation, controls engineering, or related domains.
• Experience with custom machinery, OEM equipment, or process manufacturing environments.
• Proven track record from design through startup and commissioning.
• Ability to travel 40–50% for customer sites.

Responsibilities

• Design and develop complete industrial control systems for custom machinery.
• Program PLC, HMI, and SCADA including sequencing and data collection.
• Create control narratives, specs, and standardized automation solutions.
• Lead FAT and SAT and manage commissioning at customer sites.
• Train operators and provide ongoing technical support.
• Collaborate across engineering, manufacturing, vendors, and customers.

Skills

Project management

Troubleshooting

Communication

Reading electrical schematics

Education

Bachelor's degree in Electrical/Controls/Automation/Mechatronics

Tools

Allen-Bradley ControlLogix/CompactLogix

Siemens PLCs

FactoryTalk View

WinCC

Ignition

Industrial networking (EtherNet/IP/PROFINET/Modbus/OPC-UA)

VFDs and motion control

Industrial instrumentation

Job description

We are seeking an experienced Controls Engineer to design, program, integrate, and commission automation systems for custom industrial equipment used in mixing, blending, drying, and material processing applications. This is a hands-on role involving projects from initial concept and engineering through startup, commissioning, and customer support.

Key Responsibilities

• Design and develop complete industrial control systems for custom machinery and integrated processing systems.
• Program and troubleshoot PLC, HMI, and SCADA applications, including machine sequencing, process control, recipes, diagnostics, and data collection.
• Develop control narratives, functional specifications, operating sequences, and standardized automation solutions.
• Create and maintain I/O lists, electrical schematics, network architecture, panel layouts, instrumentation specifications, and alarm strategies.
• Select and integrate PLCs, HMIs, VFDs, motors, sensors, load cells, instrumentation, safety devices, and other automation components.
• Configure industrial networks and integrate third‑party equipment using EtherNet/IP, PROFINET, Modbus TCP/RTU, OPC‑UA, and related technologies.
• Support electrical panel design and review drawings for applicable electrical and machine safety standards.
• Work with mechanical engineering, project management, manufacturing, vendors, OEMs, and customers throughout project execution.
• Participate in project planning, scheduling, budgeting, hardware/software selection, and controls deliverables.
• Develop and conduct Factory Acceptance Testing (FAT) and Site Acceptance Testing (SAT).
• Lead equipment startup and commissioning at customer sites, including loop checks, functional testing, troubleshooting, and system validation.
• Train customer operators and maintenance personnel following installation.
• Provide ongoing technical support for troubleshooting, upgrades, modernization, and retrofit projects.
• Contribute to automation standards, lessons learned, continuous improvement, remote diagnostics, and future controls platforms.
• Participate in machine risk assessments and ensure safe operation in accordance with applicable electrical, machine safety, and industry standards.

Required Qualifications

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related engineering field.
• 10+ years of experience in industrial automation, controls engineering, machine design, or manufacturing systems.
• Background with custom machinery, OEM equipment, or process manufacturing environments.
• Demonstrated experience taking controls projects from engineering/design through testing, startup, and commissioning.
• Strong experience with:
  • Allen‑Bradley ControlLogix and CompactLogix
  • Siemens PLCs
  • FactoryTalk View, WinCC, Ignition, or comparable HMI platforms
  • Industrial networking and communications
  • VFDs and motion control
  • Industrial instrumentation
  • Machine safety and safeguarding
• Ability to read and produce electrical schematics and controls documentation.
• Familiarity with SQL databases and industrial data acquisition/reporting systems.
• Strong troubleshooting, analytical, project management, communication, and customer‑facing skills.
• Ability to manage multiple engineering projects and coordinate work across internal and external teams.
• Willingness to travel approximately 40-50% for customer meetings, equipment installation, startup, commissioning, and service activities.

Preferred Experience

• Powder processing, blending, drying, pharmaceutical, food, chemical, additive manufacturing, or specialty materials equipment.
• Batch process control systems.
• UL 508A panel design requirements.
• Validation documentation such as FAT, SAT, IQ, and OQ.
• Industry 4.0, remote monitoring/diagnostics, predictive maintenance, and connected manufacturing technologies.

What You’ll Work On

You will work on highly engineered, custom industrial equipment, partnering with engineering, manufacturing, vendors, and customers to deliver automation solutions from concept through successful installation and acceptance. The role offers opportunities to influence controls standards, support modernization projects, and take on increasing technical and project leadership responsibilities.