Controls Engineer

Foster, LLC.; Putnam (CT); On-site; USD 85,000 - 120,000; Full time

Job summary

Foster, LLC. seeks a highly skilled Controls Engineer for our extrusion plant operations. You will design, program, and maintain PLC-based control systems for extrusion equipment, implement closed-loop strategies, and smooth drive and HMI integration to maximize uptime and efficiency.

The role requires expertise in Allen-Bradley and Siemens platforms, PID tuning, and strong documentation. Travel up to 15% to support US locations is expected.

Qualifications

• Proficiency in PLC programming and troubleshooting.
• Experience with drive programming and closed-loop control.

Responsibilities

• Design, program, and maintain PLC-based control systems for extrusion equipment.
• Develop and implement closed-loop control strategies for temperature, pressure, and speed regulation.
• Configure and troubleshoot drive systems (AC/DC drives, servo systems) for extrusion lines.
• Integrate and optimize HMI interfaces for operator usability and process monitoring.
• Perform system diagnostics and root cause analysis to minimize downtime.
• Collaborate with maintenance and engineering teams to support continuous improvement initiatives.
• Ensure compliance with electrical safety standards and plant procedures.
• Document control logic, wiring diagrams, and configurations for future reference.

Skills

PLC programming

Drive programming

PID tuning

Electrical schematics

Industrial communications

Reading P&IDs

Problem solving

Attention to detail

Education

Bachelors in Electrical Engineering

Tools

AutoCAD

SOLIDWORKS

TIA Portal

Job description

We are seeking a highly skilled Controls Engineer to join our extrusion plant operations team. The ideal candidate will have a strong background in drive programming, PLC systems, and closed-loop control systems. This role is critical for ensuring optimal performance, reliability, and efficiency of our extrusion processes through advanced automation and control strategies.

Key Responsibilities

• Design, program, and maintain PLC-based control systems for extrusion equipment.
• Develop and implement closed-loop control strategies for temperature, pressure, and speed regulation.
• Configure and troubleshoot drive systems (AC/DC drives, servo systems) for extrusion lines.
• Integrate and optimize HMI interfaces for operator usability and process monitoring.
• Perform system diagnostics and root cause analysis to minimize downtime.
• Collaborate with maintenance and engineering teams to support continuous improvement initiatives.
• Ensure compliance with electrical safety standards and plant operational procedures.
• Document control logic, wiring diagrams, and system configurations for future reference.

Required Qualifications

• Proficiency in PLC programming and troubleshooting:
• Allen-Bradley (Rockwell Automation) – ControlLogix, CompactLogix
• Siemens – S7 series, TIA Portal
• Experience with drive programming (e.g., ABB, Siemens, Rockwell PowerFlex).
• Strong understanding of closed-loop control systems and PID tuning.
• Familiarity with industrial communication protocols (EtherNet/IP, Profibus, Modbus).
• Ability to read and interpret electrical schematics and P&IDs.
• Excellent problem-solving skills and attention to detail.

Preferred Qualifications

• Experience in extrusion processes or similar continuous manufacturing environments.
• Knowledge of SCADA systems and data acquisition.
• Familiarity with robotics integration and advanced motion control.
• Strong project management and documentation skills.
• Ensuring all department workers adhere to the safety policies and procedures.
• Ensure operational efficiency of electrical equipment and mechanical systems through timely inspection and repair.

Qualifications

• Excellent electrical, electronic, and mechanical skills.
• Experience with Auto Cad or similar program.
• Knowledge of NEC, NFPA79, OSHA Regulations.

Education and/or Experience

• Bachelor’s degree in Electrical Engineering, Automation, or related field (or equivalent experience).
• 7+ years of experience in industrial automation and controls engineering.
• Prior experience with cGMP, ISO 13485 or ISO 9001 are preferred.
• 5-10 years work experience in a regulated industry preferred.

Mathematical Skills: Ability to add, subtract, multiply, and divide into all units of measure, using whole numbers, common fractions, and decimals.

Language/Communication Skills: Ability to read and write and follow written work instructions.

Computer Skills

• SOLIDWORKS and/or AutoCAD preferred
• Familiarity with MS Office and ability to learn new electronic maintenance recording system

Certificates, Licenses, and/or Registrations: N/A

Physical Requirements

Physical Requirements: The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this position. Reasonable accommodation may be made to enable individuals with disabilities to perform essential functions.

• Ability to stand, walk, use hands to finger, handle or feel, reach with hands and arms, climb and balance, stoop, kneel, talk, and hear.
• Ability to frequently lift and/or move up to 50 pounds unassisted, occasional lifting/moving of up to 100 pounds.

Work Environment

Work Environment: The work environment characteristics described here represent those an employee encounters while performing the essential functions of this position. Reasonable accommodation may be made to enable individuals with disabilities to perform essential functions.

• Regular exposure to fumes or airborne particles.
• Occasional exposure to moving mechanical parts and vibration.
• Normal exposure to moderate noise levels.

Travel Expectations: Up to 15% travel to support all US locations (Connecticut and Nevada).

Telework Conditions: None.

Pathogen Exposure Risk: Low.