Controls Application Engineer

Role summary

Controls Application Engineer is a role at Mixer Systems Inc. in Pewaukee, Wisconsin, United States (on-site). Posted 2026-08-11. Experience level: 2-5.

Job title

Controls Application Engineer

Company

Mixer Systems Inc.

Location

Pewaukee, Wisconsin, United States

Work arrangement

on-site

Category

Software Engineering

Experience level

2-5

Date posted

2026-08-11

Job description

Description

Position Summary

The Controls Application Engineer serves as the technical bridge between engineering, manufacturing, and customers by supporting the application, startup, commissioning, troubleshooting, and continuous improvement of Mixer Systems' batching control systems. This role focuses on ensuring electrical control systems function as intended throughout installation and commissioning while providing technical support for both new and existing equipment.

The position requires a strong understanding of industrial control systems, PLCs, HMIs, electrical schematics, and material handling equipment. While experience modifying PLC and HMI programs is important, this role is primarily focused on applying, validating, troubleshooting, and optimizing control systems rather than developing software from the ground up.

Essential Duties and Responsibilities

The essential functions include, but are not limited to the following:

Controls Application & Commissioning

Support startup, commissioning, and validation of batching plants and related equipment.

Perform I/O verification, system testing, and operational checks prior to customer startup.

Troubleshoot electrical and control system issues during manufacturing, commissioning, and customer support activities.

Modify existing PLC and HMI programs to support equipment functionality and customer requirements.

Assist with system optimization and continuous improvement initiatives.

Verify proper operation of motors, VFDs, sensors, instrumentation, and control devices.

Support remote and on-site troubleshooting of customer equipment.

Assist in diagnosing field issues and recommending corrective actions.

Technical Support

Serve as a technical resource for customers, field service technicians, production, and engineering.

Provide technical assistance during equipment installation and startup.

Support service personnel with troubleshooting electrical and controls-related issues.

Document system modifications and maintain accurate engineering records.

Assist with customer training regarding operation of batching control systems.

Engineering Support

Review electrical drawings, wiring diagrams, and bills of material for accuracy.

Assist with electrical panel layouts and control system improvements.

Recommend design improvements based on field experience and customer feedback.

Collaborate with Mechanical Engineering, Manufacturing, and Service teams to resolve technical issues.

Support testing and validation of new products and design enhancements.

Continuous Improvement

Identify opportunities to improve equipment reliability, serviceability, and ease of commissioning.

Assist in developing standard work, troubleshooting guides, and technical documentation.

Support product improvement initiatives based on customer and field feedback.

Requirements

Minimum Qualifications

Bachelor's degree in Electrical Engineering, Electrical Engineering Technology, Mechatronics, Automation, or related technical field; equivalent industry experience may be considered.

3+ years of experience supporting industrial control systems, automation equipment, or electrical systems.

Experience commissioning, troubleshooting, or supporting PLC-based industrial equipment.

Working knowledge of Allen-Bradley PLCs (Logix 5000 preferred).

Experience with FactoryTalk View Studio or similar HMI software.

Ability to modify existing PLC and HMI programs.

Ability to read and interpret electrical schematics, wiring diagrams, and technical documentation.

Strong troubleshooting and analytical problem-solving skills.

Ability to communicate technical information effectively with customers and employees.

Strong organizational skills with the ability to manage multiple priorities.

Proficient with Microsoft Office applications.

English proficiency, both verbal and written.

Preferred Qualifications

Experience with concrete batching, aggregate handling, material handling, feed mills, seed processing, or similar industrial equipment.

Experience with industrial networking and communications.

Familiarity with variable frequency drives (VFDs), instrumentation, sensors, and motor controls.

Previous field service or commissioning experience.

SQL database experience.

Electrical panel build or wiring experience.

AutoCAD Electrical or similar CAD software experience.

Work Environment

The work environment characteristics described here are representative of those an employee encounters while performing the essential functions of this position.

Work is performed in a combination of office, manufacturing, laboratory/testing, and customer environments.

Regular interaction with industrial control systems, electrical panels, automated equipment, and batching systems.

Collaborate closely with Engineering, Manufacturing, Service, Sales, and Production teams to support equipment commissioning, troubleshooting, and continuous improvement.

Frequent use of computers, engineering software, PLC/HMI interfaces, electrical test equipment, and diagnostic tools.

Occasional travel to customer facilities for equipment startup, commissioning, troubleshooting, training, and technical support.

Exposure to moving mechanical equipment, electrical systems, dust, noise, vibration, and varying indoor and outdoor environmental conditions.

Required to wear appropriate personal protective equipment (PPE) and comply with all company and customer safety policies while working in manufacturing facilities and customer job sites.

May occasionally work outside normal business hours to support equipment startup, customer schedules, or urgent technical issues.

Physical and Mental Demands

Physical Demands

The physical demands described here are representative of those that must be met by an employee to successfully perform the essential functions of this job. Reasonable accommodations may be made to enable individuals with