Senior Controls Engineer

Sonoco Products Company; Hartselle (AL); On-site; USD 122,000 - 156,000; Full time

Job summary

Sonoco Products Company is seeking a Senior Controls Engineer for the Reels Division Automation Group in the United States. The role leads electrical and controls design for high-volume manufacturing technologies across Sonoco's Reels facilities.

The engineer will design with EPLAN, develop PLCs in Studio5000, create intuitive HMIs, and integrate alarms. Responsibilities include project leadership, collaboration with Operations and Maintenance, and driving continuous improvement.

Qualifications

• BS in Electrical/Controls Engineering or equivalent experience.
• 8–10 years in controls and automation design.
• Solid knowledge of electrical control system design software (EPLAN preferred).
• Experience leading automation projects and coordinating cross-functional teams.

Responsibilities

• Design electrical and control systems for custom automation solutions using EPLAN.
• Develop and enforce process standards emphasizing safety and reliability.
• Lead change management, IP security, and documentation (drawings, code, concepts).
• Develop PLC programs in Studio5000 and HMIs.
• Provide field and shop support during fabrication, testing, and installation.
• Lead projects with internal teams and external vendors to meet scope, budget, and schedule.
• Collaborate with Operations, Maintenance, and Supply Management to ensure project success.

Skills

EPLAN

Studio 5000

HMI programming

PLC programming

Robotics

Vision systems

SCADA

Safety standards

Team leadership

Education

BS in Electrical/Controls Engineering

Tools

EPLAN Pro Panel

Studio 5000

MAPLE Systems HMIs

Ignition SCADA

Job description

From a small family business to a multi-billion-dollar global company, Sonoco has been changing the face of products and packaging since 1899 - all while keeping the heart of "People Build Businesses" alive.

Our talented people are at the core of our growth, constantly reinventing the Sonoco wheel with brilliant solutions every year. Today we are a world leader in global packaging solutions with diversified operations in over 34 countries. We're extremely proud of our portfolio of brands, our achievements in sustainability and industrialization and the groundbreaking work accomplished by our people.

Reporting directly to Sonoco Reels Division's Sr. Director of Engineering, the Senior Controls Engineer will be responsible for leading the electrical and controls design effort in the Reels Division Automation Group. They will be responsible for the design, build, integration, installation, and support of innovative controls and automation solutions for high volume, diverse manufacturing technologies for all of Sonoco's Reels facilities.

Responsibilities

What you will be doing:

• Design electrical and control systems for customized automation solutions using EPLAN.
• Development of and compliance with process standards that will ensure consistency in the process to include a specific focus on maximizing the safety performance of all solutions.
• Manage the change management process and IP security for all elements of solutions to include, but not limited to drawings, source code, and concepts.
• Actively participate in and lead collaborative brainstorming sessions to conceptualize the simplest automation solution for complex problems.
• Provide support for and assist Automation Technicians during panel fabrication, shop testing, installation, and field support.
• Develop reliable PLC programs in the Studio5000 environment.
• Develop intuitive HMI programs.
• Integrate comprehensive alarms and messaging into PLC and HMI programs.
• Provide advanced troubleshooting for automated machinery as needed.
• Collaborate with Operations and Maintenance teams to ensure equipment is properly operated and maintained.
• Support automated data collection and reliability tracking.
• Create capital project proposals that clearly communicate the opportunity and proposed solution to Plant, Divisional, and Corporate leadership teams
• Manage automation projects including supervising in-house, contract, and OEM resources to ensure projects are completed on-time and on-budget.
• Collaborate with internal Supply Management and OEM to generate general scopes and/or detailed Performance - Statement of Work documents for new assets.
• Actively collaborate with the Business Units in the Continuous Improvement Effort: Always find a way to keep improving. Maintain a working knowledge of Sonoco's products, processes, and machinery.
• Directs drafters, designers, and technicians assigned to his projects. Obtains outside resources as required to accomplish project goals.
• Coordinates projects with other departments as required.
• Makes branch plant trips or vendor visits as required to accomplish project objectives.
• Works closely with manufacturing personnel, division managers, marketing, and other disciplines as required.
• Solid knowledge of all applicable safety regulations related to controls and automation solutions
• Solid understanding and experience with electrical control system design software (EPLAN preferred)
• Overseeing lean control panel fabrication process. (leveraging EPLAN Pro Panel or similar)
• PLC and HMI programming (Studio5000 for PLC and Maple Systems for HMIs preferred)
• Robotics programming (FANUC preferred)
• Vision system development for robotic guided vision and quality inspection applications (Cognex or Keyence preferred)
• Ignition or similar SCADA system experience is a plus.
• Solid knowledge of troubleshooting equipment problems and performing complex system tests
• Creative thinking skills
• Detail-oriented personality
• Continuous improvement mindset
• Ability to define problems, collect data, establish facts, and draw valid conclusions
• Ability to communicate and collaborate effectively with other members of the development team and Sonoco leadership.
• Operates effectively in high pressure environments.

We'd love to hear from you if:

• Bachelor of Science in Electrical/Controls Engineering or similar equivalent experience.
• Minimum 8-10 Years in Controls and Automation design.

Compensation

The annual base salary range for the Engineer IV is from $122,320 to $137,610. This position is eligible for a bonus as well.

The annual base salary range for the Engineer V is from $138,320 to $155,610. This position is eligible for a bonus as well.

Benefits

*Benefits listed below are for employees located in the U.S. Specific benefits and wellbeing programs may vary depending on your location (within the U.S. or global), or if you are a union employee.

• Medical, dental, and vision coverage for you and your dependents, including FSA and HSA options
• 401(k) retirement plan with company match
• Wellbeing tools and resources to support holistic health, including an Employee Assistance Program with a variety of services
• Paid time off and holidays to recreate, rejuvenate and care for the health of yourself and family
• Variety of company paid and voluntary employee-paid insurance plans including life, personal accident, and disability insurance
• Tuition reimbursement

We are an equal opportunity employer, and we strictly prohibit and do not tolerate discrimination against employees, applicants or any other covered persons because of race, color, religion, national origin or ancestry, sex, pregnancy, sexual orientation, marital status, gender identity or expression, age, disability, genetic information, veteran status, or any legally protected characteristic.