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Sr Process Control Engineer Jobs in Madison, WI (NOW HIRING)

Hydrite

Process Controls Engineer

Cottage Grove, WI · On-site

Troubleshoot live process, instrumentation, and control system issues on the plant floor. * Own and ... Train operators, technicians, and engineers on control system use and troubleshooting.

BIOFerm

Quality Control Engineer

Madison, WI · On-site

BIOFermâ„¢ is looking for a Quality Control Engineer to ensure its renewable energy projects meet ... This position oversees quality processes throughout design, fabrication, construction, and ...

BIOFerm

Quality Control Engineer

Madison, WI

BIOFermTM is looking for a Quality Control Engineer to ensure its renewable energy projects meet ... This position oversees quality processes throughout design, fabrication, construction, and ...

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Build and maintain control plans, standardized work, and process check sheets for paint operations ... Opportunities for growth into senior process engineering, project engineering, or leadership roles.

Mastermold LLC

Paint Process Engineer

Johnson Creek, WI · On-site

$90K - $108K/yr

Build and maintain control plans, standardized work, and process check sheets for paint operations ... Opportunities for growth into senior process engineering, project engineering, or leadership roles.

Accuray

Motion Control Engineer

Madison, WI

Summary: The Motion Control Engineer is responsible for the research, planning, design, and ... Assures that quality processes are followed on projects and within the Mechanical Systems group.

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

Process Engineer We're looking for a dependable Process Engineer who will be located in our Madison ... Opportunities to grow your skills in new product development, process control, and capital ...

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

A handson technical role where your engineering expertise truly matters ... Opportunities to grow your skills in new product development, process control, and capital ...

Placon Corporation

Process Engineer

Madison, WI · On-site

$70K - $85K/yr

A hands-on technical role where your engineering expertise truly matters ... Opportunities to grow your skills in new product development, process control, and capital ...

Ametek

Senior Software Engineer

Madison, WI

$123.50K - $162.80K/yr

The Senior Software Engineer acts as a recognized technical expert and a reference for complex ... Today, our products serve a broad range of laboratory and process control applications in end ...

Ametek

Senior Software Engineer

Madison, WI · On-site

$123.50K - $162.80K/yr

The Senior Software Engineer acts as a recognized technical expert and a reference for complex ... Today, our products serve a broad range of laboratory and process control applications in end ...

Illumina, Inc.

Manufacturing Process Engineer 1

Madison, WI · On-site

$74.10K - $98.70K/yr

Based at our Wisconsin site, you will join a team of process engineers at the global leader in genetic sequencing, providing validation, process control, and project support for the equipment and ...

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All JobsSr Process Control Engineer JobsSr Process Control Engineer Jobs in Madison, WI

Sr Process Control Engineer information

See Madison, WI salary details

$75.6K

$122K

$171.8K

How much do sr process control engineer jobs pay per year?

As of May 30, 2026, the average yearly pay for sr process control engineer in Madison, WI is $122,040.00, according to ZipRecruiter salary data. Most workers in this role earn between $104,800.00 and $135,500.00 per year, depending on experience, location, and employer.

What are the key skills and qualifications needed to thrive as a Sr Process Control Engineer, and why are they important?

To thrive as a Sr Process Control Engineer, you need a strong background in chemical or electrical engineering, process optimization, and control systems design, often supported by a bachelor’s or master’s degree and relevant industry experience. Expertise with distributed control systems (DCS), programmable logic controllers (PLC), and software such as MATLAB or Simulink is typically required. Strong analytical thinking, problem-solving abilities, and effective communication skills help you address complex issues and work collaboratively with multidisciplinary teams. These skills and qualities are crucial for ensuring safe, efficient, and reliable plant operations while driving continuous improvement.

How does a Sr Process Control Engineer typically collaborate with operations and maintenance teams?

As a Sr Process Control Engineer, you will work closely with both operations and maintenance teams to ensure that control systems run smoothly and efficiently. You may be responsible for troubleshooting process irregularities, optimizing system performance, and providing technical guidance during system upgrades or shutdowns. Regular communication and collaboration with these teams are essential, as you will need their input to identify pain points and implement practical solutions. This collaborative environment helps ensure process reliability and continuous improvement across the facility.

What are Sr Process Control Engineers?

Sr Process Control Engineers, or Senior Process Control Engineers, are experienced professionals who design, implement, and optimize automated control systems used in manufacturing and industrial processes. They work to ensure that these systems operate efficiently, safely, and in accordance with industry standards. Their responsibilities often include developing control strategies, troubleshooting complex process issues, and collaborating with other engineering teams to improve production quality and reliability. Typically, they have several years of experience and may also mentor junior engineers or lead project teams.

What is the difference between Sr Process Control Engineer vs Process Control Engineer?

AspectSr Process Control EngineerProcess Control Engineer
Required CredentialsBachelor's degree in Engineering, often with 3+ years experienceBachelor's degree in Engineering or related field, entry to mid-level experience
Work EnvironmentIndustrial plants, manufacturing facilities, process industriesSimilar environments, often in manufacturing or chemical plants
Employer & Industry UsageOil & gas, chemicals, pharmaceuticals, refiningSame industries, typically as entry or mid-level roles
Common Search & ComparisonHigher responsibility, advanced skillsEntry to mid-level, foundational skills

The main difference between a Sr Process Control Engineer and a Process Control Engineer lies in experience, responsibility, and skill level. The senior role involves more complex project management and system optimization, while the process control engineer focuses on implementing and maintaining control systems. Both roles are vital in process industries and share similar work environments and industry usage.

What are popular job titles related to Sr Process Control Engineer jobs in Madison, WI? For Sr Process Control Engineer jobs in Madison, WI, the most frequently searched job titles are:
What job categories do people searching Sr Process Control Engineer jobs in Madison, WI look for? The top searched job categories for Sr Process Control Engineer jobs in Madison, WI are:
Sr Process Control Engineer jobs near you
Infographic showing various Sr Process Control Engineer job openings in Madison, WI as of May 2026, with employment types broken down into 2% As Needed, 32% Full Time, 55% Part Time, 2% Temporary, 8% Contract, and 1% Nights. Highlights an 97% Physical, 1% Hybrid, and 2% Remote job distribution, with an average salary of $122,040 per year, or $58.7 per hour.
Process Controls Engineer

Process Controls Engineer

Hydrite

Cottage Grove, WI

Other

Medical, Dental, Vision, Life, Retirement, PTO

Posted 11 days ago

Hydrite Chemical rating

6.6

Company rating: 6.6 out of 10

Based on 5 frontline employees who took The Breakroom Quiz

74th of 88 rated chemical manufacturers

Job description

WHO WE ARE

We are a company where people matter. 

We are family driven. 

We are financially strong.

And we are looking for problem-solvers to join our growing team.  

BENEFITS

  • Up to 10% Retirement Contribution
  • $600 per Year Wellness Incentive 
  • Two Weeks Starting Paid Time Off
  • Medical, Dental, and Vision - Eligible first day of the month following hire date.

JOIN A TOP WORKPLACE - https://www.youtube.com/watch?v=7nlFHnnfvhk

Process Controls Engineer

Responsible for hands-on ownership, troubleshooting, and continuous improvement of plant process control systems supporting batch and continuous chemical manufacturing operations

Primary responsibilities include:

  • Troubleshoot live process, instrumentation, and control system issues on the plant floor.
  • Own and maintain batch and continuous control strategies including recipes, phases, and equipment modules.
  • Provide technical leadership for control systems including DeltaV DCS, Allen-Bradley PLCs, and APACS.
  • Support startups, shutdowns, batch transitions, and abnormal operations.
  • Coordinate with third-party vendors for support, maintenance, and upgrades.
  • Maintain alarm management, HMI effectiveness, and operator usability.
  • Support capital projects including design reviews, FAT/SAT, commissioning, and startup.
  • Ensure compliance with site safety, regulatory, and cybersecurity requirements.
  • Develop and maintain control system standards and documentation.
  • Train operators, technicians, and engineers on control system use and troubleshooting.
  • Participate in root cause analysis and continuous improvement initiatives.
  • Maintain backups, recovery procedures, and lifecycle planning. Uphold Hydrite's Standard of Excellence through a continuous commitment to maintain quality facilities and provide quality products and services to internal and external customers
  • Perform all duties outlined in relevant SOPs and all other duties to be assigned.
  • Participate in RCRA, regulatory, health & safety and process training activities as required. Review changes/additions with your supervisor.  Must be RCRA compliant.

REPORTING STRUCTURE

  • This position reports to the Director of Engineering and Compliance

PREFERRED EXPERIENCE

  • Bachelor's degree in Engineering or equivalent experience.
  • 7+ years of experience in industrial automation within chemical or process manufacturing.
  • Strong hands-on experience with Emerson DeltaV DCS and Allen-Bradley PLC platforms.
  • Working knowledge of ISA-88 batch concepts and alarm management.
  • Strong communication, troubleshooting, and documentation skills.
  • Ability to work in a chemical manufacturing environment with required PPE.
  • Ability to climb ladders and access equipment in process areas.
  • Regular on-site presence and ability to respond to off-hours operational issues.
  •  

ADDITIONAL BENEFITS

Benefits and perks include 401k and profit sharing, medical/dental/vision/life insurance, paid time off, tuition reimbursement, adoption assistance, legal services insurance, scholarship awards for children of employees, summer picnic, community giving events, free family wellness coaching including nutritionist and fitness coach.

WANT TO STAY CONNECTED?  FIND US ON SOCIAL MEDIA

  • LinkedIn: linkedin.com/company/hydrite-chemical-co-
  • Facebook: facebook.com/hydrite
  • YouTube:https://www.youtube.com/watch?v=Bs_493NR8RI

Learn more about Hydrite on our website: www.hydrite.com/careers

Privacy Notice for California Residents: https://www.hydrite.com/Legal/Privacy-Notice-for-Employees.htm

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