Senior Controls Engineer

ALKAR-RAPIDPAK, INC.; Town of Lodi (WI); On-site; USD 90,000 - 120,000; Full time

Job summary

ALKAR-RAPIDPAK, INC. in Wisconsin seeks a Senior Controls Engineer to design automation control systems and lead projects across engineering, manufacturing and field service. You will implement Rockwell/AB PLC and HMI solutions, define control strategies, and mentor other engineers.

Travel up to 10% may be required to support startups and commissioning. The ideal candidate has 5+ years in designing and programming industrial controls for automated machinery, strong problem-solving, and a

Qualifications

• 5+ years designing and programming industrial control systems for automated machinery.
• Experience with Rockwell/Allen Bradley PLC and HMI platforms; Siemens is a plus.
• Experience with process control, VFDs, servo motion, safety PLCs, instrumentation, and multi-system integration.
• Ability to read, create, and review electrical schematics and controls documentation.
• Ability to manage several active projects while communicating priorities and decisions clearly.

Responsibilities

• Lead the controls scope from requirements through commissioning and customer acceptance.
• Design and program PLC and HMI applications using Rockwell platforms (ControlLogix/CompactLogix, Studio 5000, FactoryTalk View).
• Define control strategies, documentation, and project deliverables.
• Serve as a senior technical resource for troubleshooting and root-cause resolution in factory and customer sites.
• Review electrical schematics, panel designs, and controls documentation for safety and accuracy.
• Improve standards, reusable code, system architecture, and commissioning practices.
• Provide mentorship to controls engineers, electrical designers, technicians, and field-service personnel.
• Support customer startups and commissioning, travel up to 10%.

Skills

Rockwell/Allen Bradley PLC

HMI platforms

Siemens experience

Process control

VFDs

servo motion

safety PLCs

instrumentation

multi-system integration

electrical schematics

Education

Bachelor’s or Associate’s degree in an engineering-related discipline

Job description

Description

Position Summary

As a Senior 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 60+ 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.
• Define control strategies, documentation, and project deliverables.
• 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.
• Support customer startups and commissioning, with travel generally limited to up to 10%.

What Makes You a Great Fit

• Strong solving problems and hands‑on troubleshooting.
• Adaptable and dependable.
• Collaborative—able to work independently and as part of cross‑functional teams.
• Organized with attention to detail
• Effective communicator—clear and professional verbal and written skills.
• Committed to safety and operational excellence.
• Priority on quality, support, and doing things the right way.

Requirements

• 5+ 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.
• Proficiency with Rockwell/Allen Bradley PLC and HMI platforms; Siemens experience is a plus.
• 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.