Senior Process Controls Engineer

Job Description

Job Description

The Process Controls Engineer is responsible for leading the design, implementing, and optimizing control systems to ensure the efficient and safe operation of our diverse food and beverage manufacturing operations. This role requires a deep understanding of system architecture design, network design, instrumentation specification and selection, control panel design, PLC & HMI application development, acceptance testing, system commissioning and start-up for production systems, with an emphasis on raw material storage, processing, packaging, finished goods storage and handling, and food safety compliance, as well as a commitment to sustainability and cost-effectiveness. You will collaborate closely with cross-functional teams to develop innovative solutions and enhance automation performance. This role requires a deep understanding of instrumentation and control strategies, sizing and specifying controls systems, coordinating electrical, mechanical, packaging and process systems with a focus on maintaining high standards of quality and regulatory compliance.

Duties/Responsibilities:

• Design, implement, and optimize control systems for industrial processes.
• Collaborate with cross-functional teams to develop innovative process solutions.
• Develop controls design for P&ID’s, equipment specifications, installation specifications, instrumentation lists, controls narratives for coordination, controls schematics, and control panel design.
• Coordinate with 3rd parties for equipment engineered by others, with internal or external project team members for integration of the controls design.
• Assist in identifying suppliers & subcontractors, perform technical writing aspects in bid packages for scope definition, compile technical engineering documents for bid packages.
• Participate in bid-scope reviews, assist in analyzing proposals, lead design reviews of drawings & models, attend coordination meetings, review submittals, participate in factory acceptance testing.
• Travel to site for technical assistance, coordinate directly with Stellar field staff and subcontractors, identify and resolve issues that arise, review installations for correctness, and revise drawings for as-built conditions.
• Assist in preparing comprehensive documentation of commissioning processes, test results, and system performance.
• Provide I/O checkout support, startup activities, process system testing and commissioning activities, including functional testing, performance testing, and safety testing.
• Coordinate with clients and stakeholders for system handover, providing necessary documentation and training for operational staff.
• Troubleshoot and resolve control system issues promptly to minimize downtime.
• Maintain high standards of quality and regulatory compliance in all control system implementations.
• Provide technical support and training to team members on control systems and instrumentation.
• Stay updated with the latest advancements in control strategies and apply them to enhance process performance.
• Ensure all projects comply with industry safety regulations and standards.
• Maintain current knowledge of food manufacturing trends, regulatory requirements, and food industry-specific considerations as they relate to controls and automation.
• Other duties as assigned.

Required Skills/Abilities:

• Proficiency in control system design, software and instrumentation.
• Strong leadership and team collaboration skills.
• Thorough understanding of the food industry, process systems, & plant operations.
• Familiarity of startup and commissioning processes and procedures for process systems.
• Excellent analytical, problem-solving and troubleshooting abilities, capable of identifying and resolving issues.
• Effective communication skills, both written and verbal, including interpersonal skills.
• Innovative thinking and the ability to develop creative solutions.
• Attention to detail and strong organizational skills with ability to develop and maintain controls documentation.
• Ability to work under pressure and meet tight deadlines.
• Knowledge and understanding of government and industry regulations, and standards including safety as relates to food or beverage manufacturing systems.
• Flexibility to work in different environments and adapt to changing project requirements including new technologies and advancements.

Education/Experience:

• Bachelor’s of Science Engineering degree in Electrical, Automation, Computer Science or a related field.
• Minimum of 1-7 years of experience in process controls engineer or a similar role. Relevant professional certifications and food or beverage manufacturing systems are a plus.
• Strong understanding of control system architecture and instrumentation.
• Experience with controls design and engineering in a design-build or EPC setting.
• Experience with PLCs, HMIs, SCADA systems, and other automation tools.
• Familiarity with software development life cycle and programming languages such as ladder logic, C++, or Python.
• Proven track record of successfully managing control system projects from concept to completion.
• Experience in calibration, startup and commissioning of food or beverage process systems is preferred.
• Knowledge of cybersecurity protocols related to control systems.
• Knowledge of Process Controls that support recipe management and product repeatability.
• Knowledge of 3A, USDA, or FDA sanitation requirements and regulatory entities.
• Exposer and / or skilled in relevant software; Microsoft Office Software, AutoCAD, Procore, Bluebeam, Adobe, Power BI, and BIM / ACC is preferred.

Travel Requirements:

• Ability to travel regularly for site visits, attend project meetings, corporate training, and events.
• Ability to travel internationally, obtain and maintain a valid passport.
• Travel expected to be at least 20%.
• Flexibility to travel on short notice for urgent business needs.
• Comfortable with various modes of transportation, including flights, trains, and rental cars.
• Ability to navigate and work effectively in diverse geographical locations and time zones.
• Ability to adapt to different cultures and customs while traveling.
• Maintain a professional demeanor and appearance during business trips.
• Compliance with company travel policies and procedures.

Physical Requirements:

• Ability to use a computer, phone, iPad, printer, scanner, and other office equipment.
• Visual acuity for detailed work and computer use.
• Ability to lift, carry, and move up to 25 pounds of files, documents, and materials
• Ability to sit, stand, and walk for long periods of time, ability to climb flights of stairs and ladders.
• Ability to bend, stoop, and reach as necessary.
• Manual dexterity for operating office equipment, measuring devices, quality & testing devices.
• Ability to work around machinery during installation, startup, commissioning, and troubleshooting.
• Capability to handle occasional exposure to extreme heat, extreme cold, wet environments, and extreme odors.

About Stellar:

Stellar offers a comprehensive package which includes:

• Competitive pay based on experience
• Remote & hybrid work options for many positions
• Paid Time Off – accrue 15 days (120 hours) within first year of service
• Paid holidays
• Medical, dental, and vision insurance options
• Tax-advantaged accounts (HSA, FSA, Dependent Care FSA)
• Company-paid life and disability insurance
• 401(k) – company match with immediate vesting

Stellar, headquartered in Jacksonville, FL, is a fully integrated firm focusing on design, construction, architecture, engineering, and mechanical services worldwide for over 30 years. Stellar combines a multitude of capabilities to create buildings and systems of exceptional long-term quality, value and efficiency. From food processing plants and healthcare facilities to refrigerated warehouses, automated production lines and beyond, we offer an integrated approach to meet all our clients’ needs. 

Stellar is an Equal Opportunity Employer and does not discriminate against any applicants for employment based on their race, color, religion, sex (including pregnancy, sexual orientation, or gender identity), national origin, age, physical or mental disability, genetic information, veteran status, uniformed servicemember status, or any other status protected by law.