Senior Controls Engineer

Alkar-RapidPak, Inc.; Northern (KY); Hybrid; USD 90,000 - 120,000; Full time

Job summary

Alkar-RapidPak, Inc. seeks a Controls Engineer to design and integrate advanced automation control systems. You will collaborate across engineering, manufacturing, and field service, leading programming, testing, and commissioning efforts for complex equipment.

The role requires strong experience with Rockwell/Allen‑Bradley PLC/HMI (Studio 5000, FactoryTalk View), and a background in process control, safety, and multi-system integration. Travel is generally limited to 10%.

Qualifications

• 7+ years of experience designing and programming industrial control systems for automated machinery or OEM equipment.

Responsibilities

• Lead the controls scope for complex equipment projects from requirements through testing and customer acceptance.

Skills

Troubleshooting

Adaptability

Collaboration

Attention to detail

Strong communication

Education

Bachelor’s degree in engineering or related field

Associate’s degree in engineering or related field

Tools

Rockwell/Allen-Bradley PLC

Studio 5000

FactoryTalk View

EtherNet/IP

Siemens (beneficial)

Job description

Description

Position Summary

As a Controls Engineer at Alkar, you’ll design the latest automation control systems while collaborating across engineering, manufacturing, and field service. We’re looking for someone who has a strong technical background and versatility who can shift gears when priorities change, help others, and grow alongside a company that’s still innovating after 100+ years.

Key Responsibilities

• Lead the controls scope for complex equipment projects from initial requirements and system architecture through programming, testing, commissioning, and customer acceptance.
• Design and program PLC and HMI applications using Rockwell Automation platforms, including ControlLogix/CompactLogix, Studio 5000, and FactoryTalk View.
• Develop clear, maintainable control strategies for process systems, sequencing, PID loops, drives, motion, instrumentation, machine safety, and equipment integration.
• Translate customer specifications and internal requirements into defined controls deliverables, functional descriptions, I/O requirements, and test plans.
• Serve as a senior technical resource for difficult troubleshooting, root-cause investigation, and resolution of controls issues in the factory, remotely, and at customer sites.
• Review electrical schematics, panel designs, controls documentation, and code for safety, accuracy, maintainability, and compliance with project requirements.
• Improve programming standards, reusable code, system architecture, version control, documentation, and commissioning practices across the Controls team.
• Provide technical guidance and mentorship to controls engineers, electrical designers, technicians, manufacturing personnel, and field-service personnel.
• Work closely with Mechanical Engineering, Manufacturing, Project Management, and Field Service to identify risks early and deliver complete, reliable systems.
• Support customer startups and commissioning, with travel generally limited to up to 10%.

What Sets Alkar Apart

ALKAR combines the stability of a 100-year-old equipment manufacturer with a genuine opportunity to help modernize how complex control systems are designed, programmed, tested, and commissioned. This is not a maintenance-only or narrowly defined programming position. Your work will be visible in large, custom machines that move from concept to fabrication, factory testing, installation, and production.

• Technical influence — Help define the standards, architecture, tools, and practices that guide future controls projects.
• Full-system ownership — See the result of your decisions in complete equipment rather than owning only one small portion of a system.
• Low travel for an OEM role — Travel is generally limited to up to 10%, with most development, testing, and support performed from our Lodi facility or remotely.
• Direct access to the equipment — Work alongside the people designing, building, wiring, testing, and supporting the systems you program.
• Investment and modernization — Join a company actively investing in its people, equipment, engineering capability, and manufacturing technology.
• Flexible scheduling — We provide reasonable flexibility in work hours while maintaining the collaboration needed to support projects and factory testing.
• Stability with meaningful work — Our equipment supports food producers around the world, and long employee tenures are common throughout ALKAR.

What Makes You a Great Fit

• You enjoy solving problems and hands-on troubleshooting.
• Adaptable and dependable; you adjust to a dynamic environment without losing focus or quality.].
• Collaborative by nature—able to work independently and as part of cross-functional teams, willing to support colleagues when needed.
• Highly organized with attention to detail
• Effective communicator—clear and professional verbal and written skills.
• Aligned with a culture built on trust, longevity, and doing things the right way—not just the fast way.
• Familiarity with servo motion control, multi-system integration, and OT networking is a plus.

Work Environment & Physical Requirements

• Primarily office-based, with occasional work on the shop floor or at customer sites.
• Environments may include temperature-controlled areas (heated or refrigerated).
• Occasional lifting of up to 50 lbs may be required.

Requirements

• Typically 7+ years of experience designing and programming industrial control systems for automated machinery, OEM equipment, or systems-integration projects. Exceptional demonstrated capability may substitute for years of experience.
• Strong proficiency with Rockwell/Allen-Bradley PLC and HMI platforms; Siemens experience is beneficial but not required.
• Demonstrated ability to independently develop, debug, and commission complete control systems—not only modify existing programs.
• Strong understanding of industrial networks and communication protocols, particularly EtherNet/IP.
• Experience with process control, VFDs, servo motion, safety PLCs, instrumentation, and multi-system integration.
• Ability to read, create, and review electrical schematics and technical controls documentation.
• Ability to manage several active projects while communicating priorities, risks, and technical decisions clearly.
• Bachelor’s or Associate’s degree in an engineering-related discipline, or equivalent technical training and experience.
• Commitment to safe design, reliable execution, quality, and doing the work correctly—not simply getting it done quickly.