The Automation and Controls Manager – Packaging and Bottling is responsible for leading automation and controls systems within high-speed packaging and bottling lines. The role ensures systems deliver maximum uptime, product consistency, and integration with upstream/downstream operations. It also supports digital transformation and continuous improvement initiatives.
Develop and implement automation strategies for filling, capping, labeling, sealing, wrapping, palletizing, and bottling lines.
Optimize line balance, reduce bottlenecks, and increase Overall Equipment Effectiveness (OEE).
Ensure synchronization between mechanical, electrical, and software controls on fast-paced production lines.
Design, troubleshoot, and upgrade PLC, HMI, SCADA, servo systems, and motion control for packaging and bottling equipment.
Standardize platforms (Rockwell, Siemens, Beckhoff, Schneider, etc.) across lines and sites.
Integrate vision systems, barcoding, check-weighers, and reject mechanisms.
Enable real-time data collection and interface with Manufacturing Execution Systems (MES), historians, and ERP systems.
Implement smart sensors, machine connectivity (IIoT), and remote diagnostics to support predictive maintenance.
Support batch coding, traceability, and serialization requirements.
Ensure control systems adhere to safety standards (e.g., OSHA, CE, ISO 13849) including safety relays and interlocks.
Support Change Control, GMP, and food/pharma compliance in packaging environments.
Lead root cause analysis and FMEA for control system-related downtimes.
Lead automation scope in new line installations, upgrades, and packaging innovations.
Manage budgeting, vendor selection, FAT/SAT, and commissioning for automation packages.
Ensure scalability and standardization of solutions across plants.
Supervise a team of automation engineers, technicians, and external system integrators.
Collaborate with maintenance, IT/OT, QA, and operations to align goals and drive uptime.
Provide training and SOP development for plant technicians and operators.
Expert knowledge in packaging machine automation, motion control, and vision systems
Strong troubleshooting skills in PLCs (Rockwell, Siemens), robotics, and electrical controls
Experience with OEE improvement, TPM, Six Sigma, and digital manufacturing tools
Knowledge of GMP, HACCP, ISO 22000 in food or regulated environments
Effective communicator and cross-functional project leader
Bachelor's degree in Automation, Electrical, Mechatronics, or Control Systems Engineering
8–12 years of experience in automation roles within packaging/bottling environments
Hands-on experience with conveying systems, robotics, servo drives, and packaging sensors
Certifications in Rockwell/Siemens platforms, ISA, or PMP preferred