Sr. Controls Engineer

Mountaintop Beverage; Morgantown (WV); On-site; USD 100,000 - 150,000; Full time

Job summary

Mountaintop Beverage seeks a Senior Controls Engineer to analyze manufacturing processes, optimize production efficiencies, and lead continuous improvement initiatives in a dairy/aseptic environment. You will develop control architectures, troubleshoot equipment, and ensure safety and quality standards across filling and process lines.

The role requires strong PLC programming, electrical engineering expertise, and hands-on collaboration with operations, maintenance, and vendors to implement

Qualifications

• Bachelor's degree in Process, Controls, Automation, Electrical Engineering required.
• 5+ years of controls/electrical engineering experience in aseptic processing or equivalent GMP/FDA/ISO/USDA environment.
• Strong cause-and-effect analytical abilities to solve problems and optimize performance.

Responsibilities

• Develop the control architecture to collect data and increase line reliability.
• Create standardization of electrical components and designs.
• Provide application/control systems design for systems of varying complexity.
• Interpret vendor/customer electrical/control designs to Mountaintop standards.
• Ensure continuous production by maintaining electrical control systems.
• Support maintenance for electrical/controls preventative maintenance and troubleshooting.
• Lead technology upgrades within the plant and coordinate with electricians/contractors.
• Provide training on operation and maintenance of aseptic and ESL filling lines.

Skills

PLC Programming

Electrical Troubleshooting

Automation Systems

GMP / FDA Industry

Education

Bachelor of Engineering (Process/Controls/Electrical)

Tools

Allen Bradley PLCs

Siemens PLCs

B&R PLCs

VFDs / Servo Drives

Job description

Role Impact:

As part of a startup, early-stage company, the Senior Controls Engineerwill be critical in analyzing manufacturing processes to provide controls and support production; creating opportunities to optimize production efficiencies, while evaluating performance, and proposing and implementing continuous improvement initiatives.

In this role, the Senior Controls Engineer will serve as a resource for development and troubleshooting of production equipment; providing machine support including but not limited to safety controllers, PLC's, IPC’s, HMI's, robots, motion control, measurement systems, instrumentation, material handling systems, industrial networks, and data collection systems.

Role Responsibilities:

• Develop the control architecture to ensure that the facility is collecting the data and information to increase plant and package line reliability.
• Create standardization of electrical components and designs where possible to simply the operation.
• Provide application/control systems design and development for systems of varying complexity.
• Interpret electrical/control design from vendors/customer specifications and align with Mountaintop's standards/specs
• Ensure production is continuous by maintaining and implementing electrical control systems.
• Perform work utilizing plant electrical controls standards
• Support the maintenance team as needed for electrical/controls preventative maintenance and troubleshooting.
• Work with the Change Management Process for the overall implementation, performance, and continuous improvement of company initiatives.
• Schedule and manage electrical and/or controls upgrades within the plant. Coordinate with electricians and contractors to meet project completion dates and budgets.
• Provide Training in the operation and maintenance of Aseptic and ESL Filling and Process Lines. Participate in after-hours support for the engineering group on a rotating basis.
• Designs, builds, programs, tests, and debugs aseptic filling and process Lines and material handling systems within the facility.
• Responsible for support and functionality enhancements required for facility and processing/filling lines with a focus on safety and quality.
• Development of Software Functional Specifications (SFS)
• Support equipment programming for manufacturing, troubleshoot software and hardware issues, and support the programming of robotics.
• Troubleshoot and upgrade existing equipment to the new equipment design and implementation.
• Own the controls software/hardware product lifecycle and lead instrumentation and control systems engineering projects.
• Follow Food Safety Requirement/Standards as needed.

Supervisory Responsibilities

• Support knowledge transfer and training to team members.

Education

• Bachelor’s degree in Process, Controls, Automation, Electrical Engineering required.
• MBA preferred

Experience & Skills

• 5+ years of controls/electrical engineering experience in aseptic processing or equivalent in GMP, FDA, ISO, USDA or PMO regulated environment.
• A minimum of 2-5 years' experience in a variety of technical or operational assignments is required to demonstrate the desired industry experience.
• Strong cause-and-effect analytical abilities to solve problems. Demonstrated ability to work with operations and technical teams to define project objectives and then deploy those findings to optimize performance of the process
• Proficient in problem-solving methodologies and root cause analysis
• Proficient skills in troubleshooting electrical, process, and automation-related issues
• Aseptic manufacturing and packaging experience required.
• Dairy manufacturing environment experience preferred.
• Dairy and Aseptic process understanding preferred.
• Experience with specific equipment required. Allen Bradley, Siemens, B&R PLC’s, VFD’s, servo drives, gearboxes,
• Strong experience in PLC programming and computer programming.
• Extensive knowledge, reading and understanding electrical schematics
• Startup experience preferred
• Extensive knowledge of engineering principles and procedures.
• Excellent analytical and management skills.
• Excellent verbal and written communication skills.
• Excellent organizational skills and attention to detail.
• Excellent interpersonal skills.

Physical Requirements

• Prolonged periods of sitting at a desk and working on a computer.
• Must be able to lift up to 15 pounds at times.
• Must be able to work with equipment that contains electric magnetic components.