Process Controls Engineer

Microbial Discovery Group; Franklin (VA); On-site; USD 85,000 - 120,000; Full time

Job summary

Microbial Discovery Group seeks a Process Controls Engineer to support automation, instrumentation, and control systems in manufacturing of microorganisms and related products. You will help design, implement, and commission new equipment and processes, partnering with Engineering, Maintenance, Operations and R&D to improve safety and efficiency.

You will maintain PLC/HMI/SCADA systems, develop control logic, update documentation, and work with contractors to integrate equipment into the

Qualifications

• BS in Electrical, Automation/Controls, Mechanical, Chemical Engineering or related field.
• 0–5 years building/maintaining plant automation in manufacturing.
• Experience with PLCs, HMIs, and instrumentation (flow, pressure, temp, etc.).
• Basic knowledge of electrical panels and industrial networking.

Responsibilities

• Maintain, troubleshoot and optimize PLC, HMI and SCADA systems for manufacturing.
• Develop PLC logic and HMI interfaces for new and existing equipment.
• Troubleshoot electrical/controls issues to minimize downtime.
• Collaborate with maintenance to implement control changes with minimal production impact.
• Update P&IDs, equipment lists, schematics and control narratives.
• Coordinate with contractors and integrators for external work.
• Integrate equipment into corporate network for remote monitoring and data capture.
• Perform software updates with backups and version control.
• Collect production data into databases or historians for reporting and analysis.
• Analyze data trends to improve stability, yield and throughput.
• Support startup, commissioning and validation of new equipment and automation upgrades.
• Provide operator/training support on automated systems.

Skills

PLC programming

HMI/SCADA

Instrumentation

P&IDs & diagrams

Industrial networking

Education

Bachelor's degree in Electrical, Automation/Controls, Mechanical, or Chemical Engineering

Tools

Allen-Bradley

Siemens

ABB

FactoryTalk

AVEVA InTouch

Job description

Position Summary

The Process Controls Engineer supports the automation, instrumentation and control systems used in MDG’s manufacturing operations, including fermentation, downstream processing, drying and blending.

This hands-on role ensures that equipment used in the day-to-day manufacturing of microorganisms and blending of microbial feed and bioaugmentation products performs in optimal condition and actively participates in the design, implementation and commissioning of new equipment and processes.

The Process Controls Engineer partners with Engineering, Maintenance, Operations and R&D to enhance safety, reliability and efficiency through robust control strategies and data-driven process improvements.

Key Responsibilities

• Maintain, troubleshoot and optimize PLC, HMI and SCADA systems supporting manufacturing operations.
• Create, test and document all required PLC control logic and HMI interfaces for new and existing equipment.
• Troubleshoot and isolate equipment issues (mechanical, electrical and controls) to minimize unplanned downtime.
• Work with maintenance personnel to implement repairs and control system changes while minimizing impact to production.
• Interpret, update and help develop technical documents such as P&IDs, equipment lists, logic diagrams, schematics, control narratives and network diagrams.
• Coordinate with outside mechanical and electrical contractors and integrators to complete work outside MDG core competencies.
• Integrate existing standalone equipment into the corporate network for remote monitoring, data collection and control.
• Perform and document PLC, HMI and SCADA software updates, including backups, version control and change management.
• Develop interfaces and data flows to collect production data into databases or historians (e.g., SQL Server or similar) to support reporting and analysis.
• Analyze process data and trends to identify improvement opportunities and implement control system changes to enhance process stability, yield and throughput.
• Support startup, commissioning and validation of new equipment, automation upgrades and process changes.
• Provide training and basic troubleshooting guidance to operators and maintenance personnel on automated systems.
• Evaluate current and emerging automation technologies for potential application at MDG.

Provide support for non-routine work hours during startups, shutdowns or critical troubleshooting.

• Perform other duties as requested, directed or assigned.

Additional Responsibilities

• Participate in cross-functional continuous improvement, root cause analysis and safety initiatives.
• Contribute to the development and periodic review of standard operating procedures (SOPs) and best practices related to process controls and automation.

Work Environment

• Work is performed in a combination of office, laboratory, and fermentation production facility environments.
• Frequent interaction with manufacturing equipment and process areas, including wet, humid, dusty and noisy conditions.
• Regular collaboration with Operations, Maintenance, Engineering and R&D teams.

Minimum Qualifications

• Bachelor of Science in Electrical, Automation/Controls, Mechanical, Chemical Engineering, or closely related discipline.
• 0–5 years of experience installing, maintaining, or supporting plant-floor mechanical, electrical, and/or automation systems in a manufacturing setting.
• Working knowledge of PLCs, HMIs, and industrial instrumentation (e.g., flow, pressure, temperature, level, pH).
• Basic understanding of electrical control panels and industrial networking concepts.

Preferred Qualifications

• Experience in fermentation, biotechnology, food, pharmaceutical, or chemical manufacturing.
• Hands-on experience with PLC platforms such as Allen-Bradley, Siemens, ABB or similar, and HMI/SCADA software such as FactoryTalk, AVEVA InTouch, or equivalents.
• Familiarity with process instrumentation, industrial communication networks (e.g., Ethernet/IP, Profibus, Modbus), and OT cybersecurity best practices.
• Experience with data collection tools, historians, or basic data analytics (e.g., SQL, dashboards) to support decision-making.

Technical Skills

• PLC programming, troubleshooting, and commissioning.
• HMI/SCADA configuration, alarm management, and user interface design.
• Instrumentation calibration, configuration, and troubleshooting.
• Reading and creating P&IDs, electrical schematics, logic diagrams and control narratives.
• Root cause analysis, corrective actions, and preventive maintenance planning for control systems.
• Basic database and network concepts related to industrial automation.

Non-Technical Skills

• Strong analytical and problem-solving skills with attention to detail.
• Effective verbal and written communication, including clear documentation.
• Ability to work collaboratively in cross-functional teams and with external vendors.
• Organizational skills with the ability to manage multiple priorities in a fast-paced environment.
• Continuous improvement mindset with strong safety and quality orientation.

Licenses/Certifications

• None required; relevant certifications in controls/automation (e.g., vendor PLC certifications) are a plus.

Physical & Safety Requirements

• Mandated use of company-issued uniform and Personal Protective Equipment (PPE).
• Adherence to all company safety procedures and regulations to maintain a safe working environment.
• Majority of work is conducted in a fermentation production facility and includes frequent exposure to wet, humid, dusty, and noisy conditions.
• Work includes lifting (up to 50 lbs.), standing, walking, as well as occasional scooping, kneeling, or crouching.
• May be exposed to airborne particles and chemicals used in fermentation production facilities.

Disclaimer

Adherence to all food safety procedures as per FDA regulations, including the FDA Food Safety Modernization Act (FSMA) or any other applicable federal, state, or local food safety regulations.