Senior Controls Engineer

Job Title: Senior Controls Engineer Job Description The Senior Controls Engineer leads large web converting machinery projects and ensures successful execution of all project phases, from order intake through final site acceptance. This role combines advanced PLC, HMI/SCADA, and drive configuration expertise with close collaboration across engineering disciplines and direct customer interaction. The engineer also contributes to product standardization, software development, and mentoring and training junior staff, while helping modernize technology and introduce new automation solutions. Responsibilities Serve as the controls lead for large web converting machinery projects, taking ownership of controls-related activities from initial order intake through final site acceptance testing. Ensure the successful delivery of all phases of each project, including design, development, testing, commissioning, and customer handover. Attend and actively participate in customer meetings to gather requirements, clarify specifications, and provide technical guidance on controls solutions. Select appropriate electrical and automation components, including PLCs, drives, and related hardware, to meet performance, safety, and reliability requirements. Oversee the generation of complete and accurate electrical print packages and documentation for each project. Interface closely with Mechanical Engineering and other disciplines to integrate controls solutions with mechanical designs and overall machine functionality. Develop, program, and test PLC software, with a focus on Allen-Bradley platforms and GuardLogix safety systems. Design and implement HMI and SCADA applications to support machine operation, monitoring, and diagnostics, using tools such as Wonderware and FactoryTalk. Configure and commission VFDs and servo drives, ensuring proper operation, tuning, and integration with PLC and motion control systems. Perform machine testing and debugging to validate controls performance, safety functions, and process capability prior to shipment and installation. Provide on-site installation and start-up services, working safely in industrial environments and acting as the closer to ensure customer satisfaction during final site acceptance testing. Apply machine operator safety standards and collaborate with safety audit teams to generate operator risk assessments and certify equipment using SIL safety ratings. Assist in product standardization efforts by developing reusable controls architectures, software modules, and documentation to improve consistency and efficiency. Contribute to ongoing software development initiatives aimed at modernizing technology and incorporating new automation solutions. Train and mentor junior staff, providing guidance on programming, process controls, HMI/SCADA development, and commissioning best practices. Support continuous improvement by identifying opportunities to enhance controls performance, reliability, safety, and ease of operation across the equipment portfolio. Essential Skills At least 2 years of experience with programming and process controls on web converting, web handling, winding, or closely related technologies. Minimum of 10 years of experience with PLC programming and PLC software development, with deep expertise in Allen-Bradley platforms. Proven expertise with Allen-Bradley GuardLogix safety PLCs, including development, configuration, and troubleshooting of safety-related functions. At least 5 years of experience configuring and commissioning VFDs and servo drives in industrial automation applications. Minimum of 5 years of experience providing on-site installation and start-up services in industrial environments, including responsibility for final site acceptance testing. At least 5 years of experience working with machine operator safety standards, including practical application of risk assessments and safety certifications. Hands-on experience generating operator risk assessments and certifying equipment using SIL safety ratings. Strong PLC programming skills, including ladder logic, function block, and structured programming techniques. Solid background in process controls for continuous and discrete manufacturing operations. Experience with HMI and SCADA development, including design, implementation, and testing of operator interfaces and supervisory control systems. Ability to work safely and effectively in industrial settings, adhering to site safety practices and procedures. Strong communication skills for interacting with customers, cross-functional engineering teams, and operations personnel. Ability to lead controls aspects of complex machinery projects and drive them to successful completion. Additional Skills & Qualifications Experience with Siemens TIA Portal is a plus, including PLC and HMI configuration and programming. background with Wonderware for SCADA development is highly desirable. Experience with FactoryTalk Machine Edition and FactoryTalk Site Edition for HMI and SCADA applications is a plus. Exposure to web converting, web handling, and winding technologies, including understanding of process dynamics and tension control, is beneficial. Familiarity with modern automation and controls engineering practices, including integration of new technologies into existing equipment. Experience working within a growing engineering organization, transitioning from smaller-scale operations to larger, more standardized processes. Ability to mentor and train junior engineers and technicians on controls engineering topics. Work Environment The role sits within a dedicated controls engineering group that collaborates closely with electrical design engineers, process engineers, and Senior controls engineers focused on programming, process control, HMI, and SCADA generation. The environment offers a hybrid work model, with the ability to work from home approximately 50–75% of the time, combined with on-site work for meetings, testing, installation, and start-up activities. The organization is in a growth and modernization phase, transitioning from a smaller, family-style operation to a larger engineering-focused company, which creates opportunities to introduce new technologies and work on a diverse range of projects. The work involves time in industrial facilities during installation and commissioning, where adherence to site safety protocols and appropriate industrial attire is expected. Job Type & Location This is a Contract to Hire position based out of Paterson, NJ. Pay and Benefits The pay range for this position is $45.00 - $68.00/hr. 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. Eligibility requirements apply to some benefits and may depend on your job classification and length of employment. Benefits are subject to change and may be subject to specific elections, plan, or program terms. If eligible, the benefits available for this temporary role may include the following: • Medical, dental & vision • Critical Illness, Accident, and Hospital • 401(k) Retirement Plan – Pre-tax and Roth post-tax contributions available • Life Insurance (Voluntary Life & AD&D for the employee and dependents) • Short and long-term disability • Health Spending Account (HSA) • Transportation benefits • Employee Assistance Program • Time Off/Leave (PTO, Vacation or Sick Leave) Workplace Type This is a hybrid position in Paterson,NJ. Application Deadline This position is anticipated to close on Oct 1, 2026. 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 actalentaccommodation@actalentservices.com 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 may be reviewed using AI tools.