Controls Engineer/Maintenance Electrician

Job Summary Lead development, maintenance and continuous improvement of machine and plant control systems for a flexible PVC compounding facility. Ensure reliable, safe, and efficient automated operation of batching, mixing, extrusion dosing, conveying, and packaging lines through PLC/HMI/SCADA solutions, drives, and field instrumentation. Key Responsibilities - Design, program, debug, and commission PLC, HMI and SCADA systems for extrusion, mixers, feeders/dosing, conveyors, and auxiliary systems. - Maintain and troubleshoot controls, drives (VFDs), servo systems, instrumentation (flow, pressure, temperature, level), and pneumatic/electrical actuators to minimize downtime. - Implement and maintain safety systems: e-stops, interlocks, machine safeties, and safety PLCs per OSHA/NFPA/ISO requirements. - Lead capital and retrofit projects from requirements through commissioning: control system architecture, I/O lists, panel layouts, wiring, bill of materials, vendor coordination, testing and documentation. - Implement process control strategies (PID tuning, recipe management, closed-loop control) to improve product quality, throughput, and scrap reduction. - Support PLC/HMI/SCADA backups, version control and change management; create and maintain wiring diagrams, schematics, and control narratives. - Interface with production, maintenance, quality, and RandD to troubleshoot process anomalies and optimize compounding recipes and line performance. - Develop and deliver operator and maintenance training, standard operating procedures (SOPs), and preventive maintenance tasks for controls systems. - Support continuous improvement and reliability programs (root cause, corrective actions, OEE improvements). - Ensure compliance with electrical codes, company safety policies, and environmental regulations. Required Qualifications - Bachelors degree in electrical engineering, Controls Engineering, Mechatronics, or equivalent technical diploma with relevant experience. - 3-7 years controls experience in continuous processing or plastics/compounding/extrusion environment (preferred). - Hands-on PLC/HMI programming experience Allen Bradley/Rockwell, and Automation Direct (e.g., Productivity Series/Do-more) preferred. - Experience with SCADA/industrial HMIs (Ignition, Wonderware, FactoryTalk, etc.). - Strong skills with VFDs, motor control, PID loop tuning, instrumentation and I/O systems. - Knowledge of industrial network protocols (Ethernet/IP, Modbus, Profibus, OPC). - Proficient reading electrical schematics, ladder/function block/ST programming, and panel wiring. - Strong troubleshooting skills; able to respond to production incidents and restore operation quickly. - Good communication and project coordination skills; able to work with vendors and cross-functional teams. - Willingness to be on-call for critical outages; occasional overtime and support during commissioning. Preferred Qualifications - Direct experience with PVC compounding, batching, silos and pneumatic conveying, extrusion lines, feeders/dosing systems, and material handling. - Experience with safety PLCs and functional safety standards (ISO 13849, IEC 62061). - Experience with recipe management, batch control, and MES/ERP integration. - PLC source control and industrial cybersecurity best practices. Working Conditions - On-site in a manufacturing environment with exposure to noise, dust and moving equipment; PPE required. - Combination of office and shop-floor work; travel to vendor sites as needed. Application Materials Please submit resume, brief summary of controls projects/PLC platforms used (include Automation Direct experience if applicable), and preferred contact details.