Automation and Controls Engineer

Description

Position Overview:

The Automation and Controls Engineer owns the process control systems that run both Cayuga Milk Ingredients plants, and leads our move to a connected, data-driven operation built on Ignition. This is a hands-on, senior process controls role. We need an engineer who has spent years tuning loops, writing sequences, and commissioning process systems in a running plant - and who can stand at a panel at 2 a.m. and get a line back up.

Key Responsibilities:

Own Process Controls

• Own the control systems for continuous and batch dairy processes: receiving, separation, HTST/UHT, membranes, evaporation, drying, batching, aseptic/ESL processing, CIP, and utilities.
• Design, program, and tune control loops (PID, cascade, ratio, feed-forward) for flow, level, temperature, pressure, density, and conductivity.
• Write and maintain sequence, phase, and interlock logic to ISA-88 batch practice.
• Own instrument and valve specification, calibration requirements, and loop checks with Maintenance and Quality.
• Set and enforce controls standards: code templates, tag naming, alarm management (ISA-18.2), backups, and management of change.

Keep Production Running

• Be the senior escalation point for line stoppages, alarms, and equipment faults. Restore production safely and fast. Troubleshoot across PLCs, drives, instruments, valve clusters, and industrial networks on processing, packaging, and utilities.
• Lead root cause analysis on recurring controls downtime and put permanent fixes in place - not resets.
• Support startups, changeovers, CIP, sterilization cycles, and planned shutdowns, including off-hours when needed.
• Keep critical spares, PLC/HMI backups, and drawings current so any shift can recover.
• Take part in a shared on-call rotation for after-hours production support.

Lead Ignition SCADA

• Own the Ignition platform: gateway architecture, Perspective/Vision screens, alarming, tag historian, redundancy, and backups.
• Lead the migration of legacy HMIs (FactoryTalk View and OEM panels) to Ignition.
• Build the plant data backbone: Unified Namespace with MQTT/Sparkplug B, OPC UA, and clean, contextualized data models.

Deliver Data and Digital Tools

• Deliver MES-type functions in Ignition: OEE and downtime tracking, batch genealogy, electronic batch and CIP records, and SPC.
• Integrate plant data with Microsoft Dynamics 365 Business Central, LIMS, CMMS, and Power BI using SQL, REST APIs, and Python.
• Support food safety and quality compliance (FSMA, PMO, SQF) with reliable, auditable process data.
• Apply OT cybersecurity practice (ISA/IEC 62443) with IT: network segmentation, patching, and access control.

Capital Projects

• Lead controls scope on capital projects: functional specs, I/O lists, P&ID review, panel design review, FAT/SAT, commissioning, and handover.
• Manage integrators and OEMs to CMI controls standards so what we receive can be supported by our team.

Build the Team

• Mentor controls engineers and technicians. Review their code and designs.
• Train maintenance technicians and operators on control systems, alarms, and first-level troubleshooting.

Requirements

Education & Experience:

• Bachelor’s degree in Electrical, Controls, Chemical, Mechatronics, or Computer Engineering. Equivalent hands-on experience considered.
• Ignition Gold certification preferred (Core at minimum, or within 6 months of hire).
• Preferred: PE or Certified Automation Professional (CAP), ISA/IEC 62443 training, and NFPA 70E awareness.
• 7+ years of hands-on process controls and automation experience in a manufacturing plant, ideally dairy, food, beverage, pharma, or another regulated continuous or batch process.

Skills & Competencies:

• Rockwell ControlLogix/CompactLogix in Studio 5000 at an expert level: ladder, structured text, and function block.
• Process instrumentation and control: flow, level, temperature, pressure, density, and conductivity; control valves, VFDs, and valve clusters.
• Reading and marking up electrical drawings, loop sheets, and P&IDs.
• Industrial networking: EtherNet/IP, Modbus TCP, OPC UA, and managed switch configuration.
• SQL and Python scripting.
• Strong plus: ISA-88/ISA-95, Unified Namespace (MQTT/Sparkplug B), Sepasoft MES modules, historians (Canary, PI), and dairy equipment - HTST/UHT, separators, membranes, evaporators, dryers, aseptic/ESL fillers.

Additional Requirements:

• A true process controls background: loop tuning, sequence and phase logic, interlocks, instrumentation, and final control elements. Discrete or packaging-only automation experience does not meet this requirement.
• Hands-on Ignition experience is required: Perspective or Vision development, alarming, tag historian, gateway configuration, and scripting.
• Led controls scope on capital projects through FAT/SAT, commissioning, and startup.
• Track record troubleshooting live production equipment under time pressure in a 24/7 operation.
• Hands-on Orientation: Prefers direct troubleshooting at the panel or on the floor over prolonged administrative meetings.
• Root-Cause Problem Solving: Focuses on identifying and resolving root causes rather than temporary symptoms, ensuring all corrective actions are thoroughly documented.
• Scalable & Maintainable System Design: Builds sustainable engineering solutions that team members can easily support, while holding third-party vendors to the same quality standards.
• Clear Cross-Functional Communication: Translates complex technical issues into clear, plain language for operators, management, and external suppliers.
• Rigorous Standards & Accountability: Leads by example in maintaining high standards for code quality, safety protocols, and change control management.

Environmental Considerations:

• On site in Auburn, NY. This is not a remote or hybrid role.
• Regular time on the production floor in wet, hot, cold, and noisy areas, with required PPE.

Physical Requirements:

• Ability to navigate all areas of the facility, including office spaces, warehouse areas, and the exterior perimeter.
• Must wear required personal protective equipment (PPE) as necessary to safely perform job duties.
• Ability to stand, sit, and carry out tasks throughout a full shift, with appropriate meal breaks.
• Physically capable of standing, bending, stooping, kneeling, reaching, twisting, lifting, pushing, pulling, climbing, balancing, and crouching as needed.
• Able to lift and move items weighing up to 50 pounds independently and heavier objects with reasonable accommodations.
• Visual acuity sufficient to perform job duties accurately.
• Capable of assessing weights, judging distances, and working at various heights.

Work Schedule:

Standard working hours are Monday through Friday; however, operational needs may require variations to work hours and schedules.

Compensation:

At Cayuga Milk Ingredients, we value a fair and comprehensive approach to compensation. Our wage range for this role is determined by various factors, including skill sets, experience, training, licensure, certifications, and organizational needs. It is not typical for an employee to start at or near the top of the range for the position. Compensation decisions are made based on individual job circumstances considering skill level, previous experience, and education requirements.

Equal Opportunity Employer:

Cayuga Milk Ingredients is committed to providing equal employment opportunities to all employees and applicants without regard to race, color, religion, age, sex, national origin, disability status, genetics, protected veteran status, sexual orientation, gender identity or expression, or any other characteristic protected by federal, state, or local laws. This policy applies to all aspects of employment, including recruitment, hiring, placement, promotion, termination, layoff, recall, transfer, leaves of absence, compensation, and training.

Non-Discrimination Policy:

The contractor will not discriminate against employees or applicants for discussing or disclosing their own pay or the pay of others. However, employees with access to compensation information as part of their job duties are prohibited from disclosing this information to unauthorized individuals, except in specific circumstances outlined by applicable laws and regulations (41 CFR 60-1.35(c)).

General Statement:

All Cayuga employees recognize that the success and prosperity of the company is everyone’s responsibility. All employees are expected to treat each other in a positive, respectful, and professional manner, to be at work for their assigned shift and to work safely as a team. Employees must be self-starters who can relate to all levels of the organization.

Disclaimer:

• All requirements are subject to possible modification to reasonably accommodate individuals with disabilities.
• This job description in no way states or implies that these are the only duties to be performed by the employee occupying this position. Employees will be required to follow any other job-related instructions and to perform any other job-related duties requested by their supervisor.
• The company reserves the right to add to or revise an employee's job duties at any time at its sole discretion.
• This document does not create an employment contract, implied or otherwise, other than an “at will” employment relationship.