Controls Engineer

Job Title: Controls Engineer

Job Description

This role focuses on designing, developing, and commissioning advanced industrial control systems for high-speed manufacturing and process applications. You will architect PLC and HMI/SCADA solutions, integrate motion and safety systems, and support complex automation projects from concept through startup. The position offers the opportunity to work on diverse automation projects, collaborate with cross-functional teams, and grow professionally in a technically challenging and supportive environment.

Responsibilities

• Design, develop, and deploy comprehensive PLC programs using the Allen-Bradley Logix platform, including Studio 5000 and RSLogix 5000.

• Develop and configure HMI and SCADA applications to provide intuitive operator interfaces and robust system monitoring.

• Program and commission high-speed, multi-axis synchronized motion systems using Kinetix servo drives, virtual master axes, electronic gearing, and camming for precision manufacturing operations.

• Design, program, and optimize complex conveyor and material handling systems, including accumulation conveyors, sortation systems, palletizers, and handoffs with automated guided vehicles (AGVs) or autonomous mobile robots.

• Implement tracking, merging, diverting, and barcode or RFID scanning logic to ensure seamless product flow through high-throughput logistics and production lines.

• Design and optimize control strategies for web handling applications, including tension control, winding and unwinding, and registration for continuous web lines.

• Engineer control algorithms for extrusion processes, ensuring tight temperature regulation, pressure control, and line speed synchronization.

• Implement complex batch process sequences in alignment with industry standards such as ISA-88, ensuring reliable and repeatable operations.

• Design, tune, and troubleshoot advanced PID control loops, including cascade loops, ratio control, and feed-forward strategies to minimize disturbances and maximize process stability.

• Integrate third-party equipment, robotics, instrumentation, and vision systems into the primary control network using industrial communication protocols such as EtherNet/IP, ControlNet, and DeviceNet.

• Conduct rigorous factory acceptance testing (FAT) and site acceptance testing (SAT) to validate system performance and functionality.

• Perform on-site troubleshooting, debugging, and system startup activities to ensure successful commissioning and handover.

• Design and implement hardware and software safety systems compliant with relevant standards such as ISO and ANSI B11.19, using Allen-Bradley GuardLogix controllers and safety-rated components.

• Create and maintain detailed engineering documentation, including functional design specifications, control philosophy documents, I/O lists, cause-and-effect matrices, and comprehensive as-built code comments.

• Collaborate with cross-functional teams, communicate effectively with stakeholders, and provide technical leadership on projects in high-pressure manufacturing environments.

• Support continuous improvement initiatives by identifying opportunities to enhance system reliability, performance, and maintainability.

Essential Skills

• Bachelors degree in Electrical Engineering, Mechanical Engineering, Computer Engineering, or a related technical discipline, or equivalent practical experience.

• Minimum of 510 years of hands-on controls engineering experience in a manufacturing, machinery builder (OEM), or heavy industrial process environment.

• Expert-level proficiency with Allen-Bradley hardware and software ecosystems, including Logix controllers, GuardLogix, Studio 5000, PanelView Plus, and FactoryTalk View SE/ME.

• Strong experience in PLC programming with Allen-Bradley platforms, including development, testing, and troubleshooting.

• Demonstrated mastery of high-speed motion control and multi-axis coordination using servo drives and advanced motion profiles.

• Direct experience with continuous web handling lines, including tension control, winding and unwinding, and registration control.

• Experience in batch processing and continuous process industries, including implementation of ISA-88-based control strategies.

• Deep theoretical and practical knowledge of PID loop tuning, cascade control, ratio control, and feed-forward compensation.

• Extensive experience with conveyor systems and material handling automation architecture, including product tracking and routing.

• Requires approximately 25% travel to customer locations throughout the United States for commissioning #ACTmneng26

Job Type & Location

This is a Permanent position based out of Saint Paul, MN.

Pay and Benefits

The pay range for this position is $90000.00 - $130000.00/yr.

Individual compensation offered for this position within this range will depend on many factors, including qualifications, skills, relevant experience, job knowledge, geographic location, internal equity, and other pertinent job-related factors.

In addition to competitive compensation, the following benefits are available to eligible employees: Medical, dental, and vision insurance Health Savings Account with employer contribution Nice Healthcare Employer-paid life and AD&D insurance Voluntary supplemental insurance 401(k) plan with company match Paid time off and paid holidays Minnesota ESST and applicable paid leave benefits Opportunities for professional growth and technical development Collaborative, team-oriented culture with exposure to diverse automation projects

Workplace Type

This is a fully onsite position in Saint Paul,MN.

Application Deadline

This position is anticipated to close on Oct 15, 2026.

About Actalent

Actalent is a global leader in engineering and sciences services and talent solutions. We help visionary companies advance their engineering and science initiatives through access to specialized experts who drive scale, innovation and speed to market. With a network of almost 20,000 consultants and 5,000 clients across the U.S., Canada, Asia and Europe, Actalent serves many of the Fortune 500. We are proud to be an Engineering News-Record (ENR) Top 500 Design Firm for our engineering design services and a ClearlyRated Best of Staffing® winner for both client and talent service.

The company is an equal opportunity employer and will consider all applications without regard to race, sex, age, color, religion, national origin, veteran status, disability, sexual orientation, gender identity, genetic information or any characteristic protected by law.

If you would like to request a reasonable accommodation, such as the modification or adjustment of the job application process or interviewing process due to a disability, please email [email protected] for other accommodation options.

San Francisco Fair Chance Ordinance: Pursuant to the San Francisco Fair Chance Ordinance, for all positions located in the city and county of San Francisco, we will consider for employment qualified applicants with arrest and conviction records.

Massachusetts Lie Detector: It is unlawful in Massachusetts to require or administer a lie detector test as a condition of employment or continued employment. An employer who violates this law shall be subject to criminal penalties and civil liability.

Use of Artificial Intelligence (AI): We may use Artificial Intelligence (AI) to support parts of our hiring process, including sourcing, screening, and evaluating candidates. AI helps assess applications and qualifications, but final decisions are made by our hiring team. By applying, you acknowledge and agree that your application may be reviewed using AI tools.