Senior Controls Engineer - Personal Care Product Manufacturing

Role Overview:

We are seeking an experienced Senior Controls Engineer for a hands-on role with GEMCO, a leading manufacturer of custom industrial mixing, blending, drying, and material-processing equipment. This role will lead controls design, PLC/HMI programming, system integration, testing, and commissioning for new and retrofit projects.

Key Responsibilities:

• Design and develop complete industrial control systems.
• Program and troubleshoot PLC, HMI, and SCADA applications.
• Develop I/O lists, electrical schematics, control narratives, and network architecture.
• Integrate PLCs, VFDs, instrumentation, sensors, safety systems, and third-party equipment.
• Configure industrial communication networks and data collection systems.
• Lead FAT, SAT, startup, commissioning, troubleshooting, and validation.
• Work closely with customers, mechanical engineers, project managers, vendors, and internal teams.
• Support equipment upgrades, retrofits, customer troubleshooting, and continuous improvement.
• Ensure systems meet applicable electrical and machine safety standards.

Qualifications:

• Bachelor’s degree in electrical, Controls, Automation, Mechatronics Engineering, or related field.
• Industrial automation/controls engineering experience.
• Experience with custom machinery, OEM equipment, or process manufacturing.
• Strong experience with Allen-Bradley ControlLogix/CompactLogix and/or Siemens PLCs.
• Experience with FactoryTalk, WinCC, Ignition, or similar HMI platforms.
• Knowledge of EtherNet/IP, Profinet, Modbus, and OPC-UA.
• Experience with VFDs, motion control, instrumentation, and machine safety systems.
• Strong troubleshooting, project management, communication, and customer-service skills.
• Experience with FAT/SAT, UL 508A, batch processing, or pharmaceutical/food/chemical equipment is a plus.