Senior Automation Controls Engineer – R&D / Material Handling

Intralox; Baltimore (MD); On-site; USD 110,000 - 160,000; Full time

Benefits offered by this job

Health insurance

Dental insurance

Vision insurance

Disability insurance

401(k) plan

Paid time off

Job summary

Intralox is seeking a Senior Automation Controls Engineer to lead controls development for R&D and customer-facing material handling solutions from concept through prototype, validation, commissioning, and product handoff.

You will develop PLC/HMI software using platforms such as Rockwell, Siemens, Beckhoff/TwinCAT, or equivalent, define controls architecture, and design integration for field devices while collaborating across global teams.

Qualifications

• Bachelor’s degree in Electrical Engineering or related technical field.
• Minimum 7 years of experience in controls engineering, industrial automation, material handling, machine control, or related equipment/system design.
• Strong PLC programming experience using ladder logic and structured text on Rockwell Studio 5000, Siemens TIA Portal, Beckhoff/TwinCAT, or comparable platforms.
• Experience developing controls software for new machines, equipment platforms, or product development programs from concept through field-ready implementation.
• Experience with sensors, VFDs, HMIs, networks, safety systems, and distributed field devices.
• Experience with machine safety, safety PLCs, risk assessments, or safety-rated control systems.
• Ability to read and support electrical schematics; AutoCAD Electrical is preferred.
• Strong communication skills and ability to work with engineering, manufacturing, suppliers, field teams, and customers.
• Willingness to travel approximately 10–20% with peaks during commissioning or startup.

Responsibilities

• Lead controls development for R&D and customer-facing material handling solutions from concept to handoff.
• Develop PLC and HMI software on platforms such as Rockwell, Siemens, Beckhoff/TwinCAT, or equivalent systems.
• Define controls architecture for new equipment including network layouts and interface requirements.
• Design and integrate controls for field devices like sensors, encoders, VFDs, HMIs, and safety devices.
• Build and support prototypes to test ideas and accelerate learning.
• Create documentation, standards, and training materials for internal teams, suppliers, and customers.
• Collaborate with a global team across R&D, productization, project execution, field service, and customer support.
• Provide technical leadership and mentoring to other engineers.

Skills

PLC programming

Electrical schematics

Technical leadership

Communication skills

Mentoring engineers

Travel readiness

Education

Bachelor’s degree in Electrical Engineering

Tools

Rockwell Studio 5000

Siemens TIA Portal

Beckhoff TwinCAT

AutoCAD Electrical

Job description

This is not a routine controls engineering role focused only on implementation. This role is for an experienced engineer who can take on ambiguous, technically demanding problems and help turn them into practical, field-ready solutions.

You will work as part of an R&D team developing next-generation material handling technologies from early concept through prototype, validation, commissioning, and product handoff. The work requires strong technical judgment, creativity, and ownership. Success in this role means being able to understand the physics and behavior of a system, define the right controls approach, prototype and test quickly, and help turn promising concepts into solutions that deliver customer value.

Position Description

The Senior Automation Controls Engineer will lead controls development for R&D and customer-facing material handling solutions. This person will influence system architecture, develop and validate new concepts, and collaborate across engineering, productization, project execution, field service, and customer support.

This role is especially well suited for someone who enjoys solving complex problems from first principles, working through ambiguity, and building systems that may not have an obvious precedent.

Intralox is a division of Laitram, L.L.C., with an extensive portfolio of innovative conveyance solutions and services that improve lives and optimize businessesworldwide.

Our global workforceof over 3,000 employees in 20+ countriesconsist of reliable problem solvers, continuously developing and directly delivering solutions that have driven our customers’ growth worldwide for more than 50 years.

Intralox was founded on the principle of doing the right thing, by treating customers, employees, and suppliers with honesty, fairness, and respect. We invest heavily in these values and aim to practice our business philosophy principles every day, which is why we have been consistently recognized for innovation and workplace excellence. We believe in the power of a good idea no matter where it comes from, using trust as the foundation to how we work, and that self-managed people are our greatest asset.

We listen objectively, think creatively, and deliver results. To learn more about our company culture, philosophy, and benefits, please visit our company page.

This position is not eligible for work authorization or sponsorship.

Key Responsibilities

• Lead controls development for R&D and customer-facing material handling solutions, from concept through prototype, validation, commissioning, and product handoff.
• Develop PLC and HMI software using platforms such as Rockwell, Siemens, Beckhoff/TwinCAT, or equivalent industrial automation systems.
• Define controls architecture for new equipment and automation concepts, including network layouts, control strategies, hardware concepts, and interface requirements.
• Design and integrate controls for field devices such as photoeyes, encoders, barcode scanners, VFDs, cameras, scales, solenoids, and safety devices.
• Build and support prototypes to test new ideas, validate performance, and accelerate learning.
• Create clear documentation, standards, and training materials to help internal teams, suppliers, builders, and customers effectively use and support the solution.
• Collaborate with a global team across R&D, productization, project execution, field service, and customer support.

Supporting Responsibilities

• Provide technical input for estimating, budgeting, and proposal development related to controls scope, hardware, software, and commissioning effort.
• Support procurement and supplier coordination for controls hardware, panels, electrical components, and field devices.
• Help improve internal controls standards, reusable software libraries, commissioning checklists, and troubleshooting guides.
• Participate in design reviews, risk assessments, lessons learned, and handoff meetings.
• Provide technical leadership and informal mentoring to other engineers and project contributors.
• Contribute to the evaluation of emerging technologies relevant to controls, sensing, automation, and machine performance.
• Support prototype testing, field commissioning, troubleshooting, and continuous improvement of deployed systems.
• Partner with electrical design and project teams on control panel concepts, schematics review, bills of material, and component selection

Required Qualifications

• Bachelor’s degree in Electrical Engineering, Computer Engineering, Computer Science, Mechatronics, or a related technical field
• Minimum 7 years of experience in controls engineering, industrial automation, material handling, machine control, or related equipment/system design
• Strong PLC programming experience using ladder logic and structured text on Rockwell Studio 5000, Siemens TIA Portal, Beckhoff/TwinCAT, or comparable platforms.
• Demonstrated experience developing controls software for new machines, equipment platforms, or product development programs from early-stage concept through field-ready implementation.
• Experience developing, commissioning, and troubleshooting equipment controls involving sensors, VFDs, HMIs, industrial networks, safety systems, and distributed field devices.
• Experience with machine safety, safety PLCs, risk assessments, or safety-rated control systems.
• Ability to read and support electrical schematics and control panel designs; AutoCAD Electrical experience is preferred but not required.
• Strong communication skills and the ability to work effectively with engineering, manufacturing, suppliers, field teams, and customers.
• Experience mentoring engineers or providing technical leadership across projects.
• Willingness to travel approximately 10–20%, with occasional peaks during commissioning or startup activities.

Preferred Qualifications

• Experience with Beckhoff TwinCAT, motion control, or object-oriented PLC programming
• Experience with machine vision, industrial cameras, barcode systems, AI-based inspection, or image-based sensing
• Experience with industrial PCs, edge computing, or PC-based controls
• Experience with higher-level programming languages such as C++, Python, C#, or .NET for machine control, diagnostics, simulation, or automation tools
• Experience developing reusable controls standards, software libraries, simulation tools, or commissioning tools
• Experience with MATLAB programming
• Experience working on advanced or highly automated systems where architecture definition, prototyping, and iterative development were central to the role

What Will Make Someone Successful in This Role

The strongest candidates for this role are engineers who combine deep controls expertise with sound judgment, curiosity, and initiative. They are comfortable stepping into an undefined problem, clarifying what matters, and moving toward a practical solution. They communicate clearly, challenge assumptions constructively, learn quickly through testing, and work well in a team of capable, self-managed people.

This role is a good fit for someone who wants to do more than maintain existing systems. It is for someone who wants to help invent, prove, and scale the next generation of automation solutions.

Why Join Intralox

At Intralox, you will work on meaningful engineering problems with talented colleagues in an environment that values ideas, trust, ownership, and continuous improvement. We are serious about high standards, but we also believe great work comes from empowered teams, honest communication, and people who take pride in what they build.

If you are energized by solving hard problems, building practical solutions, and contributing to technology that has visible impact for customers around the world, this is a role where you can do some of your best work.

Intralox’s benefit program is a major part of an employee’s total compensation from the company. Hired applicants may be eligible for benefits including health, dental, vision, and disability insurance, paid time off, 401K, flexible spending account, life and AD&D insurance, long term care, tuition reimbursement, and additional voluntary benefits.

The salary range provided is a good faith estimate representative of all experience levels. Intralox considers several factors when extending an offer, including but not limited to, the role, function and associated responsibilities, a candidate’s work experience, location, education/training and key skills. Therefore, we encourage all qualified applicants to apply regardless of their salary expectations.

The position is eligible for one of the following: commissions, discretionary incentives, or production incentives according to the terms of those plans