Controls Engineer

This Controls Engineer role in Chattanooga focuses on automating roll-to-roll processing for ion-exchange media, with ownership spanning line architecture, web transport and tension control, PLC/HMI/SCADA automation, and commissioning support.

Role Overview

You will help convert multiple unit operations into a single, coordinated roll-to-roll line for ion-exchange media. Key responsibilities include designing the controls and automation layer (PLC, HMI/SCADA, recipes, and line data logging) that integrates web transport, drives, tension control, and unwind and rewind stands. You will also support commissioning leadership when unit operations are physically connected and contribute to line-level safety.

Responsibilities

• Line architecture: design and integrate unwind and rewind stands, manage roll transfer between unit operations, and establish accumulator and festoon strategies and splice station functionality.
• Web transport and tension control: support low-basis-weight nonwovens using drive sizing; implement load cell and dancer feedback; configure tension zones through nips, baths, the beam shield labyrinth, and dryers.
• Controls and automation: deliver PLC programming, coordinate drives and draw control, implement HMI/SCADA workflows, manage recipes, and coordinate interlocks with the beam systems engineer.
• Line data: select sensors and set up logging for speed, tensions, temperatures, bath parameters, and dose records, starting from day one.
• Commissioning and safety: lead commissioning during physical unit connections and support line-level safety requirements including e-stops, guarding, and LOTO.

Required Qualifications

• Education: bachelor’s degree in an engineering field (electrical or chemical engineer preferred).
• Experience: 3+ years on roll-to-roll production or pilot lines with hands-on work involving drives, tension, and controls (battery electrode coating background preferred).
• Controls background: PLC and HMI programming experience with Rockwell/Allen-Bradley or Siemens-class systems, including servo and VFD drive commissioning.
• Software tools: 1+ years using software tools such as Matlab, C++, or Python.
• Collaboration and execution: ability to work effectively in a fast-paced, demanding atmosphere.
• Troubleshooting: experience troubleshooting sensors, actuators, and electrical components.
• Problem solving: creative problem solving that integrates reactive chemistry, radiochemistry, material handling, and fluid mechanics disciplines.

Technology Stack

• PLC, HMI/SCADA
• Rockwell/Allen-Bradley, Siemens
• Matlab, C++, Python
• Servo, VFD

Additional Role Requirements

• Based in Chattanooga, Tennessee (onsite). Intermittent travel to partners’ facilities may be required.
• Must be a U.S. citizen.
• Extended hours and weekends are frequently required to support critical project milestones.

Team and Program Context

You will join a team of ten in Chattanooga delivering a demonstration line by the end of 2027. This demonstration line is intended to serve as the foundation for a greenfield manufacturing facility in Series A–B, operating at 10X scale with automated material handling and integrated back-end exchange media equipment packaging. By 2030, the program target is to achieve the world’s largest volume producer of ion-exchange media.