Process Controls Engineer

Overview

The Process Control Engineer is responsible for optimizing the performance, reliability, and safety of extrusion, thermoforming, and material-handling systems through advanced process control, automation, and continuous improvement. This role integrates engineering, controls, and process expertise to improve uptime, reduce scrap, enhance product quality, and support team capability. The engineer will develop, troubleshoot, and maintain PLC/HMI programs, servos, robotics, and automation assets while also resolving day-to-day production issues on the plant floor.

This role is based in Sayreville, NJ. Fully onsite in a Manufacturing Plant.

• Design, develop, test, and maintain control systems, PLC logic, HMIs, drives, servos, robotics, inverters, and industrial PCs.
• Maintain backups, version control, documentation, and change logs for all control programs.
• Troubleshoot equipment, process deviations, alarms, and automation failures in real time.
• Lead debottlenecking initiatives to restore process flow and increase capacity.
• Support and optimize extrusion and thermoforming processes, ensuring adherence to standards.
• Improve yield, scrap, reliability, and line efficiency using structured problem-solving.
• Support startup, commissioning, networking, and integration of new equipment.
• Develop SOPs, troubleshooting guides, and training content for operators and technicians.
• Train maintenance staff in basic electrical troubleshooting and automation fundamentals.
• Participate in plant digitization by creating dashboards, visual tools, and operator aids.
• Lead or support A3/root-cause investigations, including deviations, complaints, and incidents.
• Identify and implement automation upgrades and CI opportunities.
• Support safety through control review, LOTO validation and guarding logic.
• Maintain on-call support availability for remote or on-site troubleshooting.
• Collaborate with cross-functional teams (Maintenance, Operations, Engineering, QA, Supply Chain).
• Lead capital projects from conception to completion, including scope definition, bid evaluation, contractor coordination, timeline management, and delivering a safe and successful startup.
• Provide supervisory coverage for production operations as needed.

• Strong mechanical, electrical, electronic, and process troubleshooting skills.
• Direct PLC programming experience.
• Experience with HMI development, drives, servos, robotics, and networked automation.
• Familiarity with extrusion/thermoforming preferred.
• Experience with Honeywell or Aveva PI a plus.
• Ability to interpret electrical schematics and use CAD tools.
• Strong communication skills and ability to train technical and non-technical staff.
• Ability to diagnose complex system issues under time pressure.
• Knowledge of industrial safety requirements, including LOTO, guarding, and GMPs.

• Minimum of a Bachelor of Science degree (Chemical Engineering, Mechanical Engineering or I/E is preferred).
• Minimum of 5 years of experience in either process automation, controls, or manufacturing engineering.
• Previous experience in process automation design, commissioning, and process optimization is preferred.
• Familiarity with plant operations as well as project work in the process control discipline.
• Thermoforming/extrusion experience strongly preferred.

• Standing up to 85% of the workday (manufacturing plant setting).
• Ability to lift up to 50 lbs as needed.
• Work in accordance with all company policies and procedures regarding employment, safety, quality, product safety and legality, security, and regulatory compliance as applicable.

What makes Sabert a great place to work: Pay, Benefits And More.

Sabert is eager to attract the best, so we offer competitive compensation and a generous benefits package, including full health insurance (medical, dental and vision), 401(k), life insurance, disability and more. To learn more about our benefits .

Learn More About Sabert

We are a leading global manufacturer of innovative food packaging products and solutions. The company was founded in 1983 grounded in the purpose of reinventing food packaging to nourish and protect our…