Controls Engineer

Kforce has a client that is seeking a highly hands-on Controls Engineer to support a cutting-edge Recycling & Materials Manufacturing Pilot Plant located in Hutto, Texas. This role is significantly different from traditional automotive manufacturing controls positions and is focused on process controls, instrumentation, and continuous-process operations rather than robotics, conveyors, or discrete manufacturing automation. Summary: The ideal candidate will be capable of owning the complete controls ecosystem, from field instrumentation and I/O through PLC programming, troubleshooting, commissioning, and system optimization. This engineer will support active production campaigns, troubleshoot processes and controls issues in real time, and contribute to upcoming process expansions and equipment upgrades. This is a high-priority opening supporting rapidly growing Materials and Recycling organization and offers strong conversion potential for top performers. Key Responsibilities:

• Provide controls engineering support for active pilot plant campaigns and production runs
• Troubleshoot process equipment, PLC logic, instrumentation, and automation systems
• Investigate sequence failures, equipment stoppages, and process interruptions to determine root cause
• Support operators and technicians during plant operations
• Analyze control system performance and implement corrective actions
• Work directly within PLC code and hardware systems to identify and resolve operational issues
• Develop, modify, and troubleshoot PLC programs and control logic
• Support and optimize Siemens-based automation systems
• Work with instrumentation, sensors, valves, pumps, VFDs, and process equipment
• Configure and troubleshoot I/O systems and field devices
• Implement structured programming methodologies, reusable libraries, and organized control architectures
• Participate in safety system troubleshooting and modifications as needed
• Strong hands-on experience with Siemens PLCs and Siemens TIA Portal
• Experience with: PLC Programming; Controls Troubleshooting; Instrumentation; Electrical Systems; I/O Architecture; Commissioning and Startup Activities; Root Cause Analysis
• Experience supporting live production environments
• Experience with VFDs, drives, and drive tuning
• Strong understanding of structured programming concepts, including: Structured Text; Libraries; Modular programming; Reusable code structures; Organized tag architecture
• Strong communication skills and ability to work across multiple engineering disciplines
• Proven ability to independently troubleshoot, modify, and commission PLC-based control systems
• Ability to work from field devices through control logic and HMI systems

• Chemical Processing
• Oil & Gas
• Pharmaceutical Manufacturing
• Continuous Process Manufacturing
• Industrial Utilities
• Power Generation
• Pilot Plant Operations
• Process Manufacturing Facilities

• Experience with Beckhoff PLC systems
• Experience supporting pilot-scale manufacturing environments
• Previous controls system integration experience
• Experience leading or supporting equipment commissioning projects
• Safety PLC programming and troubleshooting
• Knowledge of safety system design and implementation
• Exposure to motion control systems