Sr. Controls Engineer

System One; Morgantown (WV); On-site; USD 90,000 - 130,000; Full time

Benefits offered by this job

Health insurance

Dental plan

401(k) plan

Job summary

System One is seeking an experienced Controls Engineer to develop and standardize control architectures for aseptic filling and packaging lines. You will interpret and implement vendor specifications, ensure continuous production, and lead projects from design to deployment, collaborating with operations and maintenance teams.

The role requires extensive PLC programming, electrical schematics literacy, and hands-on troubleshooting in aseptic manufacturing.

Qualifications

• Bachelor's degree in Process, Controls, Automation, or Electrical Engineering required; MBA preferred.
• 5+ years of controls/electrical engineering experience in aseptic processing or equivalent GMP/FDA/ISO/USDA/PMO regulated environment.
• 2-5 years of experience in technical or operational assignments demonstrating industry experience.
• Strong cause-effect analytical abilities to solve problems.
• Ability to work with operations and technical teams to optimize process performance.
• Proficient in problem-solving methodologies and root cause analysis.
• Able to troubleshoot electrical, process, and automation issues.
• Aseptic manufacturing and packaging experience required.
• Dairy manufacturing environment experience preferred.
• Experience with equipment such as Allen Bradley, Siemens, and B&R PLCs, VFDs, servo drives, and gearboxes.
• Extensive PLC programming and computer programming skills.
• Knowledge of reading electrical schematics.

Responsibilities

• Develop the control architecture to improve plant and line reliability.
• Standardize electrical components and designs to simplify operations.
• Provide control systems design for systems of varying complexity.
• Interpret vendor/customer designs and align with company standards.
• Maintain and implement electrical control systems to ensure continuous production.
• Support the maintenance team for electrical/controls preventative maintenance and troubleshooting.
• Lead instrumentation and control projects through lifecycle.
• Coordinate with electricians and contractors to meet schedules and budgets.
• Train on operation and maintenance of aseptic filling and processing lines.
• Design, build, test, and debug aseptic filling and material handling systems within the facility.

Skills

Cause-effect analysis

Troubleshooting

Cross-functional collaboration

Documentation

Problem-solving methodologies

Education

Bachelor's degree in Process, Controls, Automation, or Electrical Engineering

Tools

Allen-Bradley PLCs

Siemens PLCs

B&R PLCs

VFDs

Servo drives

Gearboxes

Job description

• Develop the control architecture to ensure the facility is collecting the data and information needed to increase plant and package line reliability.
• Create standardization of electrical components and designs where possible to simplify operations.
• Provide application/control systems design and development for systems of varying complexity.
• Interpret electrical/control design from vendor/customer specifications and align with the company's standards/specs.
• Ensure continuous production by maintaining and implementing electrical control systems.
• Perform work in accordance with plant electrical controls standards.
• Support the maintenance team as needed for electrical/controls preventative maintenance and troubleshooting.
• Work within 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 on 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.
• Design, build, program, test, and debug aseptic filling and process lines and material handling systems within the facility.
• Support and improve facility and processing/filling lines with a focus on safety and quality.
• Develop Software Functional Specifications (SFS).
• Support equipment programming for manufacturing, troubleshoot software and hardware issues, and support robotics programming.
• Troubleshoot and upgrade existing equipment to new designs and implementations.
• Own the controls software/hardware product lifecycle and lead instrumentation and control systems engineering projects.
• Follow Food Safety requirements/standards as needed.
• Support knowledge transfer and training to team members.

Requirements

• Bachelor's degree in Process, Controls, Automation, or Electrical Engineering required. MBA preferred.
• 5+ years of controls/electrical engineering experience in aseptic processing or an equivalent GMP, FDA, ISO, USDA, or PMO regulated environment.
• 2-5 years of experience in technical or operational assignments demonstrating industry experience.
• Strong cause-effect analytical abilities to solve problems.
• Ability to work with operations and technical teams to optimize process performance.
• Proficient in problem-solving methodologies and root cause analysis.
• Able to troubleshoot electrical, process, and automation issues.
• Aseptic manufacturing and packaging experience required.
• Dairy manufacturing environment experience preferred.
• Experience with equipment such as Allen Bradley, Siemens, and B&R PLCs, VFDs, servo drives, and gearboxes.
• Extensive PLC programming and computer programming skills.
• Knowledge of reading electrical schematics.
• Startup experience preferred.
• Extensive knowledge of engineering principles.
• Excellent analytical, management, verbal, written communication, organizational, and interpersonal skills.

System One, and its subsidiaries including Joulé and Mountain Ltd., are leaders in delivering outsourced services and workforce solutions across North America. We help clients get work done more efficiently and economically, without compromising quality. System One not only serves as a valued partner for our clients, but we offer eligible employees health and welfare benefits coverage options including medical, dental, vision, spending accounts, life insurance, voluntary plans, as well as participation in a 401(k) plan.

System One is an Equal Opportunity Employer. All qualified applicants will receive consideration for employment without regard to race, color, religion, sex (including pregnancy, childbirth, or related medical conditions), sexual orientation, gender identity, age, national origin, disability, family care or medical leave status, genetic information, veteran status, marital status, or any other characteristic protected by applicable federal, state, or local law.