The Senior Control Systems Engineer – Valve PLC/SCADA Integration leads the design, development, and optimization of automated valve control systems within PLC, SCADA, and MES architectures. This role is essential to ensuring hygienic process integrity, safety, and operational efficiency in critical production areas such as CIP/SIP, fluid transfer, and utility management. The engineer serves as a subject matter expert (SME) for valve sequencing logic, feedback integration, and digital system standardization across multiple manufacturing sites.
Develop and enforce standards for automated valve controls, including logic templates, SCADA design, and safety interlocks across sites.
Provide expert-level support for CIP/SIP cycle automation, valve matrix control, mixproof valve clusters, and utility system integration.
Lead technical design reviews and guide internal engineers and integrators during valve-related control system development.
Design and program structured, modular PLC logic (Rockwell, Siemens, or equivalent) for valve actuation, sequencing, CIP/SIP logic, and safe-state transitions.
Implement and maintain SCADA/HMI systems with clear visualization of valve operations, system status, trends, and alarms.
Ensure reliable communication with valve sensors, actuators, and control modules using industrial protocols (EtherNet/IP, Profinet, AS-i, IO-Link).
Lead IO mapping, functional testing, and FAT/SAT for valve control systems during installations and upgrades.
Troubleshoot advanced issues related to valve feedback failures, control logic faults, SCADA anomalies, or communication losses.
Optimize response times, diagnostics, and interlocks to improve reliability and maintain hygienic control.
Support digitalization initiatives by integrating valve controls with MES, historian, and predictive maintenance systems.
Contribute to Industry 4.0 strategies involving smart valves, edge devices, and real-time data analytics.
Ensure automated valve systems meet hygienic design standards (3-A, EHEDG) and food safety regulations (FDA, FSMA, USDA).
Maintain robust technical documentation including control narratives, IO lists, electrical schematics, and alarm matrices.
Mentor junior engineers and technicians in control logic development, commissioning techniques, and hygienic automation principles.
Collaborate with process engineers, QA, maintenance, and IT to align valve control logic with operational and compliance goals.
Advanced PLC/SCADA programming for valve networks
CIP/SIP and aseptic control logic and safe-state design
Networked automation and real-time valve diagnostics
Food safety, 3-A, EHEDG, and hygienic process compliance
Digital transformation, MES integration, and smart valve architecture
Cross-site standardization and technical leadership
Bachelor’s degree in Electrical, Control Systems, Automation, or Mechatronics Engineering
Master’s degree or related certifications (ISA, PMP) preferred
Rockwell Automation or Siemens Certified Programmer
ISA Certified Automation Professional (CAP)
HACCP, PCQI, or 3-A design training is a plus
7+ years in control systems engineering in a food, beverage, dairy, or pharmaceutical environment
Deep experience with valve actuation control, CIP/SIP systems, and process automation
Proven track record leading commissioning, troubleshooting, and cross-functional projects involving PLC/SCADA integration
Expert in Rockwell Studio 5000, Siemens TIA Portal, and SCADA platforms like FactoryTalk, Ignition, or WinCC
Strong understanding of valve logic patterns, fail-safe design, and real-time troubleshooting
Proficiency in industrial communication protocols and automation network design
Ability to mentor, lead, and standardize across multi-site operations