Senior Control Systems Engineer

ob description:

** Position located in Middlesex, NJ**

Position Overview

GEMCO is seeking a Senior Controls Engineer to lead the design, programming, integration, and commissioning of automation systems for custom industrial mixing, blending, drying, and material processing equipment. This position will play a critical role in developing machine control systems that support our customers' manufacturing operations across pharmaceutical, food, chemical, additive manufacturing, and specialty materials industries.

The successful candidate will work closely with mechanical engineers, project managers, manufacturing personnel, and customers to develop reliable, user-friendly automation solutions from concept through startup. This role requires a hands-on engineer who can balance technical expertise, project execution, and customer interaction while supporting both new equipment and retrofit projects.

About GEMCO

For more than a century, GEMCO has designed and manufactured industry-leading tumble blenders, dryers, vacuum drying systems, and custom powder processing equipment. Our reputation is built on engineering excellence, innovative solutions, and long-term customer partnerships. We specialize in delivering custom-engineered systems that improve process efficiency, product quality, and operational reliability.

Key Responsibilities

Controls System Design & Development

• Design complete control systems for industrial processing equipment and integrated production systems.
• Develop PLC, HMI, and SCADA applications to support machine operation, process control, recipe management, and data collection.
• Create functional specifications, control narratives, and machine operating sequences.
• Develop and maintain control system standards that promote consistency, scalability, and maintainability.
• Evaluate and implement emerging automation technologies to improve machine performance and customer value.
• Work with customers to develop specifications and expectations.

Electrical & Controls Engineering

• Develop:
• I/O lists
• Electrical schematics
• Network architecture drawings
• Control panel layouts
• Instrumentation specifications
• Alarm and fault management strategies
• Specify and integrate instrumentation, drives, motors, sensors, load cells, safety devices, and process equipment.
• Support panel design and review electrical drawings for compliance with applicable codes and standards.

Programming & Integration

• Program and troubleshoot PLC-based control systems.
• Develop HMI interfaces that provide intuitive operator interaction and system diagnostics.
• Configure industrial communications networks and integrate third-party equipment.
• Support database connectivity, reporting systems, and production data acquisition where required.
• Collaborate with OEM suppliers and customers during integration activities.

Project Execution

• Participate in project planning, budgeting, scheduling, and execution.
• Coordinate controls-related activities with internal teams, vendors, and customers.
• Support procurement and technical review of automation hardware and software.
• Ensure controls deliverables are completed on schedule and within project requirements.

Testing & Commissioning

• Develop and execute Factory Acceptance Tests (FAT) and Site Acceptance Tests (SAT).
• Lead machine startup and commissioning activities at customer facilities.
• Perform troubleshooting, loop checks, functional testing, and system validation.
• Provide operator and maintenance training following installation.

Customer Support & Continuous Improvement

• Assist customers with troubleshooting, upgrades, and system improvements.
• Support retrofit and modernization projects for existing GEMCO equipment.
• Document lessons learned and incorporate improvements into future designs.
• Help develop standardized automation platforms across product lines.

Safety & Compliance

• Design systems that comply with applicable electrical, machine safety, and industry standards.
• Participate in machine risk assessments and safety system reviews.
• Support implementation of safe machine operation and maintenance practices.

Required Qualifications

Education

• Bachelor's degree in Electrical Engineering, Controls Engineering, Automation Engineering, Mechatronics, or a related engineering discipline.

Experience

• 5 years of experience in industrial automation, controls engineering, machine design, or manufacturing systems.
• Experience supporting custom machinery, OEM equipment, or process manufacturing environments.
• Proven experience managing projects from design through commissioning.

Technical Skills

• Strong experience with:
• Allen-Bradley ControlLogix and CompactLogix platforms
• Siemens PLC platforms
• FactoryTalk View, WinCC, Ignition, or comparable HMI software
• Knowledge of industrial communication protocols including:
• Ethernet/IP
• Profinet
• Modbus TCP/RTU
• OPC-UA
• Experience with:
• Variable frequency drives (VFDs)
• Motion control systems
• Industrial instrumentation
• Safety circuits and machine safeguarding
• Familiarity with SQL databases and industrial data collection systems.
• Ability to read and create electrical schematics and control documentation.

Professional Skills

• Strong analytical and troubleshooting abilities.
• Excellent written and verbal communication skills.
• Ability to manage multiple projects simultaneously.
• Customer-focused mindset with strong interpersonal skills.

Preferred Qualifications

• Experience with powder processing, blending, drying, pharmaceutical, food, or chemical manufacturing equipment.
• Knowledge of batch process control systems.
• Familiarity with UL 508A panel design requirements.
• Experience with validation protocols including FAT, SAT, IQ, and OQ documentation.
• Exposure to Industry 4.0 technologies, remote diagnostics, and predictive maintenance systems.

Travel Requirements

• Ability to travel approximately 40–50% for customer meetings, equipment startup, commissioning, and service support.

Pay: $110,000.00 - $140,000.00 per year

Benefits:

• 401(k)
• Dental insurance
• Health insurance
• Life insurance
• Paid time off
• Vision insurance

Work Location: In person