Job Description

Job Description

Job Description

Description:

Position Overview:

We are seeking a skilled Controls Engineer with extensive experience in PLC and HMI software within the dairy ingredients manufacturing industry. This role involves partnering closely with Operations and Design Engineering to enhance and develop Aseptic and Extended Shelf Life (ESL) processes. The Controls Engineer will play a critical role in ensuring product quality, food safety, and adherence to production specifications.

Job Responsibilities:

· Facility Startup Support: Lead the startup and commissioning of the new Aseptic ESL facility for Cayuga Milk Ingredients.

· Automation Design & Installation: Design and implement plant-wide automation systems, including PLCs and HMIs.

· System Monitoring & Maintenance: Oversee automated system performance, conduct regular maintenance, and troubleshoot issues to minimize downtime.

· Documentation Management: Record all modifications to equipment and systems, ensuring accurate and comprehensive documentation.

· Production Support: Respond to production issues promptly and provide technical support to resolve operational problems.

· MES/BMS Coordination: Assist with Manufacturing Execution System (MES) and Building Management System (BMS) activities and coordination.

· SOP Development: Aid in creating and updating Standard Operating Procedures (SOPs) for department processes.

· Automation Solutions Implementation: Introduce automation solutions to optimize operations and minimize manual intervention.

· Cross-Department Collaboration: Work closely with production, maintenance, supply chain, and accounting teams to integrate automation systems.

· Technical Documentation: Develop design specifications, user manuals, and troubleshooting guides for automated solutions.

· Compliance & Safety: Adhere to all environmental, GMP, HAACP, and OSHA regulations, ensuring a safe working environment and maintaining PPE standards.

· Technical Competency: Ensure processing equipment functions per SOPs and verify operational accuracy.

· Communication & Relationship Building: Communicate effectively, establishing strong working relationships across departments and providing clear, detailed reports to senior management.

· Independence & Task Management: Execute assigned projects independently and manage multiple tasks effectively.

· Availability: Occasionally work off-shift hours, including nights and weekends, to support 24/7 facility operations.

Essential Knowledge/Skills:

Technical Skills:

· PLC programming (Allen-Bradley, Siemens) with the ability to write and troubleshoot code.

· HMI design experience (AVEVA, FactoryTalk View) and familiarity with process databases (Historian).

· Proficiency in industrial networks (Ethernet/IP, DeviceNet, ControlNet).

· Ability to read and modify Process & Instrumentation Drawings (P&IDs).

· PID loop tuning and VFD setup experience (Allen-Bradley PowerFlex, Danfoss, Eaton).

· Expertise in digital and analog measurements (temperature, pressure, flow, speed, weight) and experience with discrete sensors.

Organizational & Communication Skills: Strong organizational, teamwork, and communication abilities, with proficiency in Microsoft Office, AutoCAD, and reporting.

Availability: Willingness to work flexible shifts as needed, including holidays, nights, and weekends.

Education/Experience:

Bachelor’s degree in electrical engineering, Mechanical Engineering, or Computer Science.

Minimum 5 years as a Programmer/Controls Engineer in a manufacturing setting, preferably dairy or food production.

Environmental Considerations:

· Must be able to work in environments with varying temperatures.

· Potential exposure to ingredients used in food manufacturing, including allergens.

· May encounter chemicals commonly used in food processing and distribution facilities.

Physical Requirements:

· Ability to navigate all areas of the facility, including office spaces, warehouse areas, and the exterior perimeter.

· Must wear required personal protective equipment (PPE) as necessary to safely perform job duties.

· Ability to stand, sit, and carry out tasks throughout a full shift, with appropriate meal breaks.

· Physically capable of standing, bending, stooping, kneeling, reaching, twisting, lifting, pushing, pulling, climbing, balancing, and crouching as needed.

· Able to lift and move items weighing up to 50 pounds independently and heavier objects with reasonable accommodations.

· Visual acuity sufficient to perform job duties accurately.

· Capable of assessing weights, judging distances, and working at various heights.

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