Controls Engineer- CO

Company Overview: We design, develop and manufacture case packers and tray packing solutions for flexible and other tough-to-handle packages such as doypacks, pillow bags, and four-sided sealed bags. Built for around-the-clock operation, these solutions have a worldwide reputation for their quick change-over, flexibility, speed, and comprehensive design. Our Integrated state-of-the-art technologies include gravity, pick and place, wrap-around, and vision-guided robotics.

At BPA, we are absolutely passionate about innovation. It adds fun and inspiration to our work that people need to excel. Our customers stimulate innovation by developing new needs, and we are on a never-ending quest to find a better, simpler way. BPA has no innovation budget. Innovation is what we are.

Position: We are seeking a Controls Engineer at our Longmont, CO location to develop the software that drives high-speed, vision-guided robotic systems. Our machines make split-second decisions — tracking products on moving conveyors, coordinating multi-robot cells, and executing precision picks at speeds that push the limits of what industrial automation can do. If you want to write code that makes real things move fast, this is the role.

You will design and build control systems spanning ABB industrial robots, Allen-Bradley PLCs, Cognex machine vision, and emerging platforms like Beckhoff/TwinCAT and ABB OmniCore. You will own your projects from concept through field startup — estimating, designing, programming, testing at FAT, installing at customer sites, and supporting production. This is not a desk-only job. You will be on the floor with the machines, tuning servo axes, debugging vision algorithms, and watching your system run at full speed before it ships.

You will work alongside a small, experienced team of controls engineers and collaborate directly with electrical, mechanical, and project management — plus the customers who depend on these systems running 24/7.

What Makes This Role Different:

· Variety — Robots, vision, PLCs, HMIs, servo motion — often all on the same project. No two machines are the same, and the problems are never boring.

· Real machines, real speed — You will watch your code run production at full rate. When it works, you know it. When it doesn’t, you fix it on the spot.

· Ownership — You own your projects from first line of code through customer signoff. No handoffs to another team — you see it through.

· Always learning — Our technology stack is evolving fast. We invest in formal vendor training, team training weeks, and give engineers time to explore new tools and methods.

· Customer-facing — You work directly with customers during FAT and field startups. They know your name, and they call you when it matters.

Duties include but are not limited to:

· Program ABB industrial robots using RAPID for high-speed pick-and-place, palletizing, and complex multi-axis motion — and push cycle times to their limits.

· Build and tune Cognex vision systems that guide robots in real time — product detection, inspection, and dynamic tracking on moving conveyors.

· Develop PLC programs on Allen-Bradley ControlLogix in Studio 5000, with emerging work on Beckhoff TwinCAT servo platforms.

· Design control system architectures that tie robots, vision, servo motion, and PLC sequencing into a single coordinated machine.

· Design and develop operator HMI applications using FactoryTalk Optix.

· Simulate and validate robot cells in ABB RobotStudio — reach studies, cycle time optimization, and collision avoidance before the machine hits the floor.

· Collaborate with the applications group to evaluate schedule, budget, and technical feasibility of new projects.

· Integrate and commission complete automation systems, coordinating across electrical, mechanical, and software disciplines.

· Troubleshoot electrical, pneumatic, and mechanical systems and their interactions with control software.

· Align and calibrate precision servo-driven equipment.

· Operate machines during testing and production phases. Tune parameters to optimize machine performance.

· Calculate and evaluate automation system efficiencies. Perform basic statistical analysis on machine data.

· Contribute to the standard code library through code reviews, modular design, and documentation — with an emphasis on field-serviceability.

· Use Git and GitHub for version control and collaborative code review.

· Assist with the installation and commissioning of equipment at customer facilities.

· Participate in lessons-learned reviews and contribute to continuous improvement of engineering processes.

· Make customer site visits to resolve field issues and support ongoing operations.

· Be available for on-call support after normal working hours when needed.

· Research new industry technologies and share findings with the team.

· Mentor junior engineers and contribute to knowledge transfer across the team.

· Ensure the highest quality in all phases of a project.

· Periodically travel up to 25% in the United States and internationally.

· Perform other duties as assigned.

Education/Experience & Qualifications:

· Bachelor’s degree (or equivalent) in Electrical Engineering, Computer Science, Mechatronics, or related field.

· 5 years of experience in a controls engineering or software development role involving industrial automation, control system design, and troubleshooting. However, a combination of experience and/or education will be taken into consideration.

· Demonstrated ability to develop and troubleshoot complex automation software across multiple platforms.

· Demonstrated competence with software standardization, modular design, and version control practices.

· Demonstrated ability to troubleshoot integrated electrical, pneumatic, and mechanical systems.

· Demonstrated competence with industrial machine vision applications.

· Understanding of precision positioning and servo-driven motion systems.

· Strong communication skills — ability to coordinate effectively with cross-functional teams, project managers, and customers.

· Ability to work independently while contributing to a collaborative team environment.

Preferred Qualifications:

· Experience programming ABB industrial robots (RAPID / RobotStudio / RobotWare).

· Experience with ABB OmniCore controllers.

· Experience with Allen-Bradley/Rockwell Automation ControlLogix and Studio 5000.

· Experience with Beckhoff TwinCAT and servo control platforms.

· Experience with Cognex vision systems (In-Sight, VisionPro, or VisionSuite).

· Experience with FactoryTalk Optix or similar HMI development platforms.

· Familiarity with Git-based version control and code review workflows.

· Experience with packaging, food & beverage, or consumer goods automation.

At this time, BPA will not sponsor a new applicant for employment authorization for this position.

BPA prides itself on the quality of its employees and as such, candidates who receive an employment offer will be required to successfully pass a drug screen and a background check.

BPA offers an opportunity to grow and develop your career in an environment that provides a fulfilling workplace for employees, creates an environment for continuous learning, and embraces the ideas and diversity of others. In addition, we offer a market-competitive salary ranging between 85k and 110k annually as well as an annual performance bonus, a robust benefits package including a majority employer-paid employee health, dental, vision, life, and disability; 20-days of PTO during the first year of employment, as well as 401(k) with a 6% match.

BPA is an Equal Opportunity Employer, Minorities/Females/Disabled/Veterans.