Controls Engineer

Controls EngineerThis role designs, programs, and commissions advanced automation and control systems for complex manufacturing, material handling, and process applications. The Controls Engineer develops PLC and HMI/SCADA solutions on the Allen-Bradley Logix platform, integrates motion, safety, and third-party equipment, and supports full project lifecycles from system architecture through startup and documentation. The position offers opportunities to work on diverse automation projects, collaborate with cross-functional teams, and contribute to high-performance industrial systems.ResponsibilitiesDesign, develop, and deploy comprehensive PLC programs using the Allen-Bradley Logix platform, including Studio 5000 and RSLogix 5000.Develop, configure, and maintain HMI and SCADA applications to support operator interfaces and supervisory control.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 weblines.Engineer control algorithms for extrusion processes, ensuring precise temperature regulation, pressure control, and line speed synchronization.Implement complex batch process sequences in alignment with industry standards such as ISA-88.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.Plan and execute rigorous factory acceptance testing (FAT) and site acceptance testing (SAT), including system debugging, troubleshooting, and on-site commissioning.Design and implement hardware and software safety systems using Allen-Bradley GuardLogix controllers and safety-rated components in compliance with relevant safety standards such as ISO and ANSI B11.19.Create and maintain detailed engineering documentation, including functional design specifications, control philosophy documents, I/O lists, cause-and-effect matrices, and fully commented as-built code.Collaborate with cross-functional teams, vendors, and customers to clarify requirements, resolve issues, and ensure successful project delivery.Lead or support projects in high-pressure manufacturing environments, ensuring systems meet performance, reliability, and safety expectations.Essential SkillsBachelor's degree in Electrical Engineering, Mechanical Engineering, Computer Engineering, or a related technical discipline, or equivalent practical experience.Minimum of 8–10+ 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 ControlLogix, GuardLogix, Studio 5000, PanelView Plus, and FactoryTalk View SE/ME.Proven experience in PLC programming for Allen-Bradley platforms, including development, troubleshooting, and optimization.Demonstrated mastery of high-speed motion control and multi-axis coordination using Kinetix servo drives and related motion technologies.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 batch sequences.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, including architecture, product tracking, and high-throughput logistics applications.Familiarity with integration to WMS (Warehouse Management Systems) or MES (Manufacturing Execution Systems) for material handling routing.Strong working knowledge of industrial networking architecture, including EtherNet/IP topology, managed switches, VLANs, and device-level ring (DLR) configurations.Excellent troubleshooting capabilities for complex control systems in manufacturing or industrial environments.Strong cross-functional communication skills and the ability to work independently or lead projects in high-pressure settings.Job Type & LocationThis is a Permanent position based out of South Saint Paul, MN.Pay and BenefitsThe 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 projectsWorkplace TypeThis is a fully onsite position in South Saint Paul, MN.Application DeadlineThis position is anticipated to close on Sep 7, 2026.About ActalentActalent 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.