Controls Application Engineer Jobs in Pewaukee, WI

Position Summary

The Process Controls Engineer supports the automation, instrumentation and control systems used in

MDG’s manufacturing operations, including fermentation, downstream processing, drying and blending.

This hands-on role ensures that equipment used in the day-to-day manufacturing of microorganisms and

blending of microbial feed and bioaugmentation products performs in optimal condition and actively

participates in the design, implementation and commissioning of new equipment and processes. The

Process Controls Engineer partners with Engineering, Maintenance, Operations and R&D to enhance

safety, reliability and efficiency through robust control strategies and data-driven process improvements.

Key Responsibilities

• Maintain, troubleshoot and optimize PLC, HMI and SCADA systems supporting manufacturing

operations.

• Create, test and document all required PLC control logic and HMI interfaces for new and existing

equipment.

• Troubleshoot and isolate equipment issues (mechanical, electrical and controls) to minimize

unplanned downtime.

• Work with maintenance personnel to implement repairs and control system changes while

minimizing impact to production.

• Interpret, update and help develop technical documents such as P&IDs, equipment lists, logic

diagrams, schematics, control narratives and network diagrams.

• Coordinate with outside mechanical and electrical contractors and integrators to complete work

outside MDG core competencies.

• Integrate existing standalone equipment into the corporate network for remote monitoring, data

collection and control.

• Perform and document PLC, HMI and SCADA software updates, including backups, version

control and change management.

• Develop interfaces and data flows to collect production data into databases or historians (e.g.,

SQL Server or similar) to support reporting and analysis.

• Analyze process data and trends to identify improvement opportunities and implement control

system changes to enhance process stability, yield and throughput.

• Support startup, commissioning and validation of new equipment, automation upgrades and

process changes.

• Provide training and basic troubleshooting guidance to operators and maintenance personnel on

automated systems.

• Evaluate current and emerging automation technologies for potential application at MDG.
Provide support for non-routine work hours during startups, shutdowns or critical troubleshooting.

• Perform other duties as requested, directed or assigned.

Additional Responsibilities

• Participate in cross-functional continuous improvement, root cause analysis and safety initiatives.

• Contribute to the development and periodic review of standard operating procedures (SOPs) and

best practices related to process controls and automation.

Work Environment

• Work is performed in a combination of office, laboratory, and fermentation production facility

environments.

• Frequent interaction with manufacturing equipment and process areas, including wet, humid,

dusty and noisy conditions.

• Regular collaboration with Operations, Maintenance, Engineering and R&D teams.

Minimum Qualifications

• Bachelor of Science in Electrical, Automation/Controls, Mechanical, Chemical Engineering, or

closely related discipline.

• 0–5 years of experience installing, maintaining, or supporting plant-floor mechanical, electrical,

and/or automation systems in a manufacturing setting.

• Working knowledge of PLCs, HMIs, and industrial instrumentation (e.g., flow, pressure,

temperature, level, pH).

• Basic understanding of electrical control panels and industrial networking concepts.

Preferred Qualifications

• Experience in fermentation, biotechnology, food, pharmaceutical, or chemical manufacturing.

• Hands-on experience with PLC platforms such as Allen-Bradley, Siemens, ABB or similar, and

HMI/SCADA software such as FactoryTalk, AVEVA InTouch, or equivalents.

• Familiarity with process instrumentation, industrial communication networks (e.g., Ethernet/IP,

Profibus, Modbus), and OT cybersecurity best practices.

• Experience with data collection tools, historians, or basic data analytics (e.g., SQL, dashboards)

to support decision-making.

Technical Skills

• PLC programming, troubleshooting, and commissioning.

- HMI/SCADA configuration, alarm management, and user interface design.

• Instrumentation calibration, configuration, and troubleshooting.

• Reading and creating P&IDs, electrical schematics, logic diagrams and control narratives.

• Root cause analysis, corrective actions, and preventive maintenance planning for control

systems.

• Basic database and network concepts related to industrial automation.

Non-Technical Skills

• Strong analytical and problem-solving skills with attention to detail.

• Effective verbal and written communication, including clear documentation.

• Ability to work collaboratively in cross-functional teams and with external vendors.

• Organizational skills with the ability to manage multiple priorities in a fast-paced environment.

• Continuous improvement mindset with strong safety and quality orientation.

Licenses/Certifications

• None required; relevant certifications in controls/automation (e.g., vendor PLC certifications) are a

plus.

Physical & Safety Requirements

• Mandated use of company-issued uniform and Personal Protective Equipment (PPE).

• Adherence to all company safety procedures and regulations to maintain a safe working

environment.

• Majority of work is conducted in a fermentation production facility and includes frequent exposure

to wet, humid, dusty, and noisy conditions.

• Work includes lifting (up to 50 lbs.), standing, walking, as well as occasional scooping, kneeling,

or crouching.

• May be exposed to airborne particles and chemicals used in fermentation production facilities.

Disclaimer

Adherence to all food safety procedures as per FDA regulations, including the FDA Food Safety

Modernization Act (FSMA) or any other applicable federal, state, or local food safety regulations.

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