Senior Controls Engineer
Sonoco · Hartselle, AL
- Level
- Senior
- Team
- Controls
- Base pay
- $122k–$138k
- Degree
- Required
- Experience asked
- 10+ years
- Industry
- Packaging
- Posted
- 16 days ago
The role in 30 seconds
A senior controls role at Sonoco (packaging) in Hartselle, AL. From a small family business to a multi-billion-dollar global company, Sonoco has been changing the face of products and packaging since 1899 — all while keeping the heart of “People Build Businesses” alive.
- They ask for
- 10+ years · degree required
- Tools it names
- Lean, PLC, Robotics, Automation
- Base pay
- $122k–$138k
- Day to day
- some off-shift / weekend coverage
Read from the posting. The full description is below.
From the plant jobs report · week of October 19, 2026
Controls Engineer roles in the US: typical posted base $97k–$141k. This one lists $122k–$138k.
Median of the low and high ends of 286 live postings that list pay, out of 877 controls engineer openings in the US, read from manufacturers' own careers sites.
Alabama plant jobs report →Pay by team and state →What moves pay →
How this role compares
Against 14 other live controls postings in Alabama.
- Experience asked
- More than usual (10+ vs 5+)
Similar roles usually ask 5+ years.
Skills these teams ask for most
- ✓ PLC 87%
- ✓ Automation 87%
- ✓ Robotics 60%
- EHS / safety 40%
- ✓ Lean 33%
- Root cause 27%
✓ = this posting asks for it too. % = share of similar postings that mention it.
At a glance
Pulled from the posting text. If it's not listed here, the posting didn't say.
How to get in at this plant
Five moves over a week or two. The first one takes ten minutes.
- 1
Pick 2–3 people on the Controls team at Sonoco
Engineers who joined in the last year or two reply the most. Use the team search on this page to find them.
- 2
Send a short, curious note
One real question about their work. No favors yet. Each person gets a different note, written for this role.
- 3
Turn a reply into a short call
Questions worth asking about this team:
- What does a normal week look like on your team?
- How does off-shift and weekend coverage work?
- How did you land the job? What stood out in your interviews?
- 4
Apply with someone vouching for you
If the call went well, ask whether they’d pass your résumé to the hiring manager. Send your résumé link, apply that day, and let them know.
- 5
Bring proof to the interview
One page of before-and-after numbers from projects you led: scrap, OEE, cycle time, cost. Plant managers hire on results.
This plant: Sonoco in Hartselle
3 other open roles at this site.
- Industrial Maintenance Reliability Technician · Reliability · Technician
- Senior Industrial Maintenance Reliability Technician · Reliability · Technician
- Maintenance Supervisor · Reliability · Supervisor
Full description from SonocoAs posted on their careers site.ShowHide
What you will be doing
- ◆Design electrical and control systems for customized automation solutions using EPLAN.
- ◆Development of and compliance with process standards that will ensure consistency in the process to include a specific focus on maximizing the safety performance of all solutions.
- ◆Manage the change management process and IP security for all elements of solutions to include, but not limited to drawings, source code, and concepts.
- ◆Actively participate in and lead collaborative brainstorming sessions to conceptualize the simplest automation solution for complex problems.
- ◆Provide support for and assist Automation Technicians during panel fabrication, shop testing, installation, and field support.
- ◆Develop reliable PLC programs in the Studio5000 environment.
- ◆Develop intuitive HMI programs.
- ◆Integrate comprehensive alarms and messaging into PLC and HMI programs.
- ◆Provide advanced troubleshooting for automated machinery as needed.
- ◆Collaborate with Operations and Maintenance teams to ensure equipment is properly operated and maintained.
- ◆Support automated data collection and reliability tracking.
- ◆Create capital project proposals that clearly communicate the opportunity and proposed solution to Plant, Divisional, and Corporate leadership teams
- ◆Manage automation projects including supervising in-house, contract, and OEM resources to ensure projects are completed on-time and on-budget.
- ◆Collaborate with internal Supply Management and OEM to generate general scopes and/or detailed Performance – Statement of Work documents for new assets.
- ◆Actively collaborate with the Business Units in the Continuous Improvement Effort: Always find a way to keep improving. Maintain a working knowledge of Sonoco’s products, processes, and machinery.
- ◆Directs drafters, designers, and technicians assigned to his projects. Obtains outside resources as required to accomplish project goals.
- ◆Coordinates projects with other departments as required.
- ◆Makes branch plant trips or vendor visits as required to accomplish project objectives.
- ◆Works closely with manufacturing personnel, division managers, marketing, and other disciplines as required.
- ◆Solid knowledge of all applicable safety regulations related to controls and automation solutions
- ◆Solid understanding and experience with electrical control system design software (EPLAN preferred)
- ◆Overseeing lean control panel fabrication process. (leveraging EPLAN Pro Panel or similar)
- ◆PLC and HMI programming (Studio5000 for PLC and Maple Systems for HMIs preferred)
- ◆Robotics programming (FANUC preferred)
- ◆Vision system development for robotic guided vision and quality inspection applications (Cognex or Keyence preferred)
- ◆Ignition or similar SCADA system experience is a plus.
- ◆Solid knowledge of troubleshooting equipment problems and performing complex system tests
- ◆Creative thinking skills
- ◆Detail-oriented personality
- ◆Continuous improvement mindset
- ◆Ability to define problems, collect data, establish facts, and draw valid conclusions
- ◆Ability to communicate and collaborate effectively with other members of the development team and Sonoco leadership.
- ◆Operates effectively in high pressure environments.
Show full description ↓Show less ↑
From a small family business to a multi-billion-dollar global company, Sonoco has been changing the face of products and packaging since 1899 — all while keeping the heart of “People Build Businesses” alive.
Our talented people are at the core of our growth, constantly reinventing the Sonoco wheel with brilliant solutions every year. Today we are a world leader in global packaging solutions with diversified operations in over 34 countries. We're extremely proud of our portfolio of brands, our achievements in sustainability and industrialization and the groundbreaking work accomplished by our people.
Reporting directly to Sonoco Reels Division’s Sr. Director of Engineering, the Senior Controls Engineer will be responsible for leading the electrical and controls design effort in the Reels Division Automation Group. They will be responsible for the design, build, integration, installation, and support of innovative controls and automation solutions for high volume, diverse manufacturing technologies for all of Sonoco’s Reels facilities.
We'd love to hear from you if
- •Bachelor of Science in Electrical/Controls Engineering or similar equivalent experience.
- •Minimum 8-10 Years in Controls and Automation design.
Benefits
- •Medical, dental, and vision coverage for you and your dependents, including FSA and HSA options
- •401(k) retirement plan with company match
- •Wellbeing tools and resources to support holistic health, including an Employee Assistance Program with a variety of services
- •Paid time off and holidays to recreate, rejuvenate and care for the health of yourself and family
- •Variety of company paid and voluntary employee-paid insurance plans including life, personal accident, and disability insurance
- •Tuition reimbursement