Controls Engineer

Job Description:\n\n \n Controls Engineer\n Location: 2577 AR-59, Decatur, ARJob Type: Full-Time, On-Site\n About United Petfood\n United Petfood is a private label producer of high-quality dry & wet pet food, biscuits and snacks. We are a Belgian family business with 25 high-tech pet kitchens in Europe and the US.\n Joining us, means joining an international, passionate and driven team with one common goal: a healthy planet filled with healthy pets! But it doesn’t stop there: we truly care about building encouraging, supportive, long-lasting partnerships, both inside as well as outside of our fast-growing family company. By only working with the very best ingredients and most innovative technology available, we ensure a spot in which you can grow, bloom and make thousands of pets happy worldwide!\n Position Summary\n The Controls Engineer is responsible for the design, programming, troubleshooting, documentation, and continuous improvement of plant-wide automation, instrumentation, electrical controls, and manufacturing control systems at United Petfood's Decatur, Arkansas facility.\n This position provides technical expertise in Programmable Logic Controllers (PLCs), Human-Machine Interfaces (HMIs), Supervisory Control and Data Acquisition (SCADA) systems, industrial networking, and process control integration. The Controls Engineer supports production equipment reliability, automation projects, and the effective integration of control systems throughout the manufacturing process.\n Working closely with Maintenance, Production, Engineering, Operations, and external vendors, this role identifies opportunities to improve equipment performance, reduce downtime, enhance process efficiency, and maintain safe, reliable manufacturing operations.\n The ideal candidate combines hands-on industrial controls experience with strong technical problem-solving, project management, and communication skills.\n Duties & Responsibilities\n Industrial Automation & Controls Engineering\n \n Design, develop, program, modify, and maintain PLC-based automation and control systems supporting manufacturing and facility operations.\n Develop and maintain HMI, SCADA, and graphical operator interface applications.\n Program, configure, and troubleshoot Allen-Bradley ControlLogix controllers using RSLogix 5000 or Studio 5000 software.\n Support Add-On Instructions (AOIs), reusable control logic, and structured programming practices.\n Configure and maintain industrial control networks, including EtherNet/IP communications and managed industrial switches.\n Design and engineer control and instrumentation systems to support production processes, equipment, and utilities.\n Support the integration of manufacturing equipment, instrumentation, and control systems with plant-wide software and data collection platforms.\n Develop and implement software modifications and customized control solutions based on operational requirements.\n Maintain accurate PLC programs, HMI applications, control system backups, configuration files, and technical documentation.\n Support plant and corporate software initiatives, system upgrades, and automation technology rollouts.\n \n Electrical Systems & Instrumentation\n \n Design, evaluate, and support electrical control systems for manufacturing equipment and facility utilities.\n Configure, calibrate, and troubleshoot industrial instrumentation, including sensors, transmitters, load cells, weighing systems, and process measurement devices.\n Program, configure, and troubleshoot variable frequency drives (VFDs), including Allen-Bradley PowerFlex systems.\n Read, interpret, develop, and maintain electrical schematics, control panel layouts, wiring diagrams, and instrumentation drawings.\n Support control panel design, equipment wiring modifications, and electrical system improvements.\n Perform input/output (I/O) loop testing, wire tracing, and control circuit troubleshooting.\n Evaluate electrical and instrumentation components for equipment upgrades, replacements, and new installations.\n Support control systems associated with process utilities, including steam, water, compressed air, and other facility systems.\n Ensure controls and instrumentation work is performed in accordance with applicable electrical standards and established company safety procedures.\n \n Equipment Troubleshooting & Production Support\n \n Provide technical support to Maintenance and Production personnel in diagnosing and resolving automation, instrumentation, and electrical control system issues.\n Troubleshoot PLC programs, HMIs, VFDs, sensors, communication networks, and related industrial automation equipment.\n Support controls-related troubleshooting on extruders, mixers, dryers, conveyors, coating systems, packaging equipment, and other manufacturing machinery.\n Investigate recurring equipment faults, control system failures, and process interruptions to identify root causes.\n Develop and implement corrective actions that improve equipment reliability and minimize unplanned downtime.\n Assist with equipment startups, commissioning, testing, and validation following repairs, upgrades, or system modifications.\n Collaborate with Maintenance personnel to identify opportunities for preventive maintenance and improved controls system reliability.\n Provide technical guidance to operators and maintenance technicians on equipment controls, system operation, and troubleshooting procedures.\n Respond to urgent production-related controls issues as operational needs require.\n \n Automation Projects & Continuous Improvement\n \n Plan, coordinate, and execute automation, instrumentation, and electrical controls projects from concept through implementation.\n Develop technical specifications, equipment requirements, and project scopes for control system upgrades and new installations.\n Support the selection, procurement, installation, and commissioning of controls and instrumentation equipment.\n Coordinate with equipment manufacturers, contractors, vendors, and internal project teams.\n Perform and document technical design reviews to ensure proposed systems meet operational, safety, and quality requirements.\n Participate in project budgeting, cost estimation, scheduling, and contract administration.\n Monitor project progress and manage assigned work within established cost and schedule requirements.\n Identify opportunities to improve production efficiency, process consistency, equipment reliability, and product quality through automation.\n Support manufacturing process improvements using control system data, equipment performance information, and operational feedback.\n Stay informed of advancements in industrial automation, instrumentation, and manufacturing controls technology.\n \n Documentation, Training & Systems Support\n \n Develop and maintain accurate controls system documentation, including PLC programs, electrical drawings, control narratives, system configurations, and operating procedures.\n Establish and maintain appropriate backups and version control for automation programs and system configurations.\n Develop Standard Operating Procedures (SOPs), troubleshooting guides, and technical training materials.\n Train Maintenance Technicians, Production Operators, and other employees on new or modified control systems.\n Provide technical support during equipment installations, upgrades, and process changes.\n Coordinate with internal IT personnel when supporting industrial networks, software applications, and manufacturing system integration.\n Maintain effective communication with Maintenance, Production, Operations, and Engineering leadership regarding system performance, project status, and technical concerns.\n Perform other related duties as assigned.\n \n Required Qualifications\n \n High school diploma or equivalent required.\n Demonstrated experience programming, troubleshooting, and maintaining industrial PLC-based control systems in a manufacturing environment.\n Working knowledge of Allen-Bradley ControlLogix PLCs and RSLogix 5000 or Studio 5000 programming software.\n Experience with industrial automation, electrical controls, instrumentation, and process control systems.\n Ability to read, interpret, and troubleshoot electrical schematics, wiring diagrams, and equipment control documentation.\n Experience programming, configuring, or troubleshooting HMI and SCADA systems.\n Knowledge of industrial communication networks, including EtherNet/IP.\n Ability to configure and troubleshoot industrial drives, sensors, and control instrumentation.\n Strong electrical and mechanical troubleshooting skills.\n Ability to independently diagnose complex control system issues and develop effective solutions.\n Strong computer skills, including Microsoft Office applications and Windows-based software.\n Effective verbal and written communication skills with the ability to work collaboratively with Production, Maintenance, Engineering, and management.\n Strong organizational, time management, and problem-solving skills.\n Ability to manage multiple priorities and support production operations in a fast-paced manufacturing environment.\n \n Preferred Qualifications\n \n Bachelor's degree or technical degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related field.\n Three or more years of experience in industrial controls engineering, automation, or PLC programming.\n Previous experience in food, pet food, beverage, or other continuous-process manufacturing environments.\n Advanced experience with Allen-Bradley ControlLogix, Studio 5000, and Add-On Instruction (AOI) programming.\n Experience with FactoryTalk View SE, Wonderware HMI/SCADA platforms, Wonderware Historian, or similar industrial software.\n Experience with VBA scripting, SQL databases, industrial data reporting, or Dream Report applications.\n Familiarity with object-oriented or modular programming principles.\n Experience with Allen-Bradley PowerFlex VFDs, including the 525 series.\n Experience configuring and troubleshooting Stratix managed industrial network switches.\n Experience using AutoCAD or similar electrical design software.\n Experience with load cells, scale controllers, process instrumentation, and industrial weighing systems.\n Knowledge of industrial utility control systems, including steam, water, and compressed air.\n Experience managing automation projects, equipment installations, and contractor coordination.\n Familiarity with manufacturing data collection, process monitoring, and continuous improvement methodologies.\n \n Knowledge, Skills & Abilities\n \n Strong technical understanding of industrial automation, PLC programming, and electrical control systems.\n Ability to diagnose and resolve complex electrical, instrumentation, and controls-related equipment failures.\n Knowledge of process control principles and manufacturing system integration.\n Ability to interpret technical drawings, equipment manuals, control schematics, and system documentation.\n Strong analytical and logical problem-solving abilities.\n Ability to design and implement practical automation improvements that support production efficiency and equipment reliability.\n Strong project management skills, including budgeting, scheduling, and coordination of technical resources.\n Ability to communicate complex technical information clearly to employees with varying levels of technical knowledge.\n Ability to train and support Maintenance and Production personnel on industrial control systems.\n Strong attention to detail and commitment to accurate documentation.\n Ability to work independently while collaborating effectively with cross-functional teams.\n Commitment to continuous improvement, operational excellence, and safe manufacturing practices.\n \n Workplace Safety\n \n Follow all company safety policies, procedures, and applicable regulatory requirements.\n Comply with electrical safety requirements, Lockout/Tagout (LOTO), machine guarding, and other applicable industrial safety procedures.\n Ensure automation and controls modifications maintain required equipment safeguards, interlocks, and protective systems.\n Complete required safety documentation and report deviations from established standards.\n Participate in mandatory safety training and consistently use required personal protective equipment.\n Immediately report unsafe conditions, near misses, injuries, and other workplace safety concerns.\n Support safe equipment startups, commissioning activities, and maintenance operations.\n \n Quality & Food Safety\n \n Follow applicable Good Manufacturing Practices (GMPs), sanitation procedures, and food safety requirements.\n Ensure control system modifications and automation improvements support established product quality and process requirements.\n Complete required quality and food safety documentation and report deviations from established standards.\n Participate in mandatory food safety and quality training.\n Follow applicable BRCGS food safety and quality management system requirements and established company procedures.\n Identify and report equipment conditions, control system failures, or process deviations that may affect food safety or product quality.\n Support corrective actions necessary to maintain food safety and quality system integrity.\n \n Work Environment & Physical Requirements\n \n Work is performed in office, maintenance, and active manufacturing environments.\n Regular presence on the production floor is required to troubleshoot equipment, support projects, and perform system assessments.\n Exposure to noise, dust, moving machinery, electrical equipment, and varying temperatures.\n Ability to stand, walk, bend, kneel, climb stairs and ladders, and access production equipment as necessary.\n Ability to work in confined spaces or elevated areas when appropriately trained, authorized, and following required safety procedures.\n Ability to lift and move equipment, tools, and materials weighing up to 50 pounds, with assistance or mechanical lifting equipment when appropriate.\n Must be able to wear required personal protective equipment and follow applicable safety procedures.\n Flexibility to support equipment breakdowns, system installations, commissioning activities, and production needs across multiple shifts, including occasional overtime or after-hours support.\n \n Why Join Us?\n At United Petfood, we believe in investing in our employees and providing opportunities for growth and development. As our Controls Engineer, you will play a critical role in supporting plant automation, improving equipment reliability, and advancing manufacturing technology at our Decatur facility.\n This position offers the opportunity to work with industrial automation systems, lead technical improvemen