Controls Technician

Controls Technician

The Controls Technician supports high-speed manufacturing operations by troubleshooting and resolving automation and control issues that impact production, quality, and safety. This role independently performs advanced diagnostics on automation, instrumentation, and control systems for automated food processing, robotic, and material transfer equipment. The Controls Technician leads engineering updates and commissioning of automation modifications, designs and implements control solutions for existing and new production lines, and drives preventive maintenance and reliability initiatives. The position also provides technical leadership, documentation, and training to ensure standardized, safe, and efficient automation practices across the facility.

Responsibilities

• Troubleshoot and resolve automation and control issues that affect production output, product quality, and employee safety.
• Independently perform advanced troubleshooting on automation, instrumentation, and control systems for automated food processing, robotic, and material transfer systems.
• Lead engineering updates, changes, testing, and commissioning of automation modifications for multiple high-speed production lines.
• Design, implement, and recommend automation solutions for existing equipment and new production line projects.
• Perform scheduled and condition-based preventive maintenance on automation and control systems to reduce failures and extend equipment life.
• Document completed work in the computerized maintenance management system (CMMS) through detailed maintenance work orders, and create and prioritize follow-up work as needed.
• Research, recommend, and implement automation improvements to enhance equipment reliability, uptime, and overall performance.
• Plan, lead, and execute automation preventive maintenance initiatives to minimize unplanned downtime and improve line efficiency.
• Apply creative problem-solving and root cause analysis to identify systemic automation issues and implement long-term corrective actions.
• Train, coach, and mentor operators, maintenance technicians, and peers on automation systems and procedures, with a particular focus on packaging and high-speed equipment.
• Lead and support special projects related to automation upgrades, retrofits, and new equipment installations.
• Collaborate with peers and cross-functional partners to share technical expertise and help standardize automation practices across the facility.
• Conduct obsolescence assessments of control systems, identify high-risk components, and develop upgrade and replacement strategies.
• Recommend automation spare parts and help manage critical automation inventory to ensure availability of key components.
• Perform additional instrumentation and electrical duties as assigned to support plant operations and reliability.
• Communicate effectively with production, maintenance, engineering, and leadership to coordinate work, resolve issues, and support continuous improvement initiatives.

Essential Skills

• Minimum 45 years of experience in industrial automation or controls within a manufacturing environment; 5+ years preferred, especially in food or high-speed packaging.
• Associates degree in Electrical Engineering Technology, Automation, Mechatronics, or a related field, or an equivalent combination of education and experience.
• Strong knowledge of control panel design, layout, and troubleshooting.
• Extensive hands-on experience with Allen-Bradley PLCs, including platforms such as PLC-5 and related systems.
• Proficiency with Allen-Bradley VFDs and HMIs in a production environment.
• Experience with PLC programming and troubleshooting in fast-paced manufacturing settings, including plastics or similar industries.
• Strong troubleshooting skills in controls engineering, electrical systems, and automation platforms.
• Hands-on experience with SCADA systems for monitoring and control.
• Ability to read and interpret electrical, hydraulic, and pneumatic schematics accurately.
• Proficiency with Microsoft Word, Excel, and Outlook for documentation, reporting, and communication.
• Demonstrated capability to act as a technical leader and trainer within assigned plant areas or machine centers.
• Strong understanding of automation, instrumentation, and control products and related engineering principles.
• Proven ability to communicate effectively and resolve issues across multiple departments and organizational levels.

Additional Skills & Qualifications

• Experience with Allen-Bradley software tools such as RSLogix and related platforms for PLC configuration and troubleshooting.
• Familiarity with legacy and current PLC platforms, including PLC-5 and similar systems used in high-speed manufacturing.
• Experience with FactoryTalk for visualization, data collection, and control integration.
• Ignition or similar SCADA/IIoT platform experience is a plus.
• Experience in fast-paced manufacturing environments, including food processing, high-speed packaging, or plastics.
• Familiarity with automation suppliers and OEM equipment, including integration and support of vendor systems.
• Strong problem-solving mindset with the ability to conduct root cause analysis and develop sustainable solutions.
• Comfort leading automation-related projects, upgrades, and retrofits from planning through commissioning.
• Ability to mentor and coach others on automation systems, safety practices, and standardized procedures.

Work Environment

This is an onsite role in a food manufacturing facility that primarily produces pasta products. The typical schedule is Monday through Friday from 7:00 a.m. to 3:30 p.m., with on-call support rotation approximately once every three weeks to assist with urgent automation and controls issues. The environment is fast-paced and production-oriented, with high-speed packaging lines, automated processing equipment, and modern control systems. Teams work closely together in a supportive, welcoming, and community-oriented culture that emphasizes respect, teamwork, and long-term relationships. Leadership is approachable and focused on collaboration, shared success, and work-life balance, treating employees as individuals rather than numbers. The organization offers on-the-job training and skill development, internal workshops, and leadership development programs, along with a strong promote-from-within philosophy across operations, maintenance, engineering, quality, and leadership roles. Employees observe nine holidays per year; when scheduled to work on a holiday, they receive premium pay for hours worked plus additional holiday pay, as well as an extra floating holiday that can be used at their discretion. Employees receive paid sick days in addition to other time-off programs and have access to monthly appointment time. The facility environment includes standard manufacturing conditions appropriate for food production, with attention to safety, cleanliness, and compliance with industry standards.

Job Type & Location

This is a Permanent position based out of Winchester, VA.

Pay and Benefits

The pay range for this position is $93000.00 - $105000.00/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.

Holidays observe 9 holidays per year; if employees are scheduled to work on a holiday they receive 2x their hourly rate, plus 8 hours Holiday Pay. They also get an additional Floating Holiday they can use at their discretion, separate from PTO. Sick Days Employees receive 2 paid sick days per year in addition to usable points and PTO. We also have a monthly 2h appointment allowance.

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 View email address on click.appcast.io 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