What You'll Learn
- âś“How electrical controls technicians earn $65K-$100K programming PLCs and industrial automation systems
- âś“PLC platforms: Allen-Bradley (Rockwell), Siemens, Schneider Electric, Mitsubishi, Omron
- âś“HMI/SCADA systems, robotics integration, motor controls, and VFD programming
- ✓5 career paths: Electrician → Controls Technician → Controls Engineer → Automation Engineer → Engineering Manager
- âś“Top industries: Automotive, food processing, pharmaceuticals, packaging, robotics
Industry Overview: Programming Robots Without a CS Degree
Electrical controls technicians are the bridge between electricians and software engineers in modern manufacturing. While traditional electricians wire circuits and install motors, controls technicians program the logic that makes machines think—using Programmable Logic Controllers (PLCs) to automate assembly lines, coordinate robotic arms, optimize production flows, and troubleshoot complex industrial systems.
Think of it as "robot programming for people who like working with their hands." You'll spend part of your day writing ladder logic code on a laptop, and part of your day climbing inside machinery, tracing wires, replacing sensors, and watching your code bring a 100-foot production line to life. It's intellectual problem-solving meets blue-collar troubleshooting—and manufacturers are desperate for people who can do both.
The field is experiencing explosive growth due to:
- •Manufacturing Automation Boom: U.S. manufacturing is reshoring production and automating heavily—smart factories need controls technicians to program, maintain, and optimize systems
- •Skilled Trades Gap: Baby boomer controls technicians are retiring faster than new technicians are trained—massive shortage of qualified PLC programmers
- •Industry 4.0 / Smart Manufacturing: IoT sensors, data analytics, predictive maintenance require controls technicians who understand both electrical systems and digital networks
- •Robotics Integration: Collaborative robots (cobots), AGVs (automated guided vehicles), and vision systems all require PLC integration and programming
- •Food Safety and Pharma Regulations: FDA/USDA compliance requires sophisticated automated controls for traceability, temperature monitoring, and batch tracking
The result: $65K-$100K salaries, excellent job security, and the satisfaction of seeing your code control multi-million-dollar production systems. If you want a career that combines tech skills with hands-on work, this is it.
Salary & Compensation: What Controls Technicians Earn
Electrical Controls Technician Pay Scale 2025
Pay by Industry (2025)
| Industry | Entry ($50K-$65K) | Experienced ($65K-$85K) | Senior ($80K-$95K) |
|---|---|---|---|
| Automotive Manufacturing | $55K - $70K | $70K - $90K | $85K - $105K |
| Food & Beverage Processing | $52K - $68K | $68K - $85K | $80K - $98K |
| Pharmaceuticals / Medical Devices | $58K - $72K | $72K - $92K | $88K - $110K |
| Packaging / Bottling | $50K - $65K | $65K - $82K | $78K - $95K |
| Oil & Gas / Petrochemical | $60K - $75K | $75K - $95K | $90K - $115K |
| Water/Wastewater Treatment | $48K - $62K | $62K - $78K | $75K - $90K |
Pay by Region (2025)
| Region | Entry Level | Experienced | Senior |
|---|---|---|---|
| Detroit / Midwest Auto Corridor | $55K - $68K | $70K - $88K | $85K - $105K |
| Gulf Coast (TX, LA) Petrochemical | $58K - $72K | $75K - $92K | $90K - $110K |
| California (Bay Area, LA, San Diego) | $62K - $78K | $78K - $98K | $95K - $118K |
| Southeast (NC, SC, GA, TN) | $50K - $62K | $65K - $80K | $78K - $92K |
| Midwest Manufacturing (OH, IN, WI) | $52K - $65K | $68K - $85K | $82K - $98K |
đź’° Overtime and Premium Pay
Controls technicians earn significant overtime during:
- • Plant Shutdowns: Time-and-a-half or double time during scheduled maintenance shutdowns (automotive plants, food processing)
- • Equipment Installation: New production line commissioning often requires 60-80 hour weeks at premium rates
- • Emergency Troubleshooting: Line-down situations pay emergency call-out rates ($100-$150/hour in some plants)
- • Weekend/Night Work: Programming and testing during non-production hours commands shift differentials
- • Travel Projects: System integrators pay per diem + travel time for on-site commissioning nationwide
Total compensation for experienced controls techs regularly exceeds $100K+ with overtime.
PLC Platforms & Control Systems: The Tools You'll Master
The "programming languages" of industrial automation are PLC platforms—proprietary systems made by major automation vendors. Each platform has its own programming software, ladder logic syntax, and hardware ecosystem. Mastering 2-3 platforms makes you highly employable.
Major PLC Platforms (by Market Share)
1. Allen-Bradley / Rockwell Automation (40% Market Share)
The industry standard in North America. If you only learn one PLC platform, learn Allen-Bradley. Dominates automotive, food processing, and general manufacturing.
- • Programming Software: Studio 5000 Logix Designer (formerly RSLogix 5000), Connected Components Workbench
- • PLC Families: CompactLogix (small-medium), ControlLogix (large), Micro800 (micro)
- • Programming Languages: Ladder logic, structured text, function block diagram, sequential function chart
- • HMI/SCADA: FactoryTalk View (HMI), FactoryTalk SCADA
- • Common Industries: Automotive (GM, Ford, Stellantis heavily use AB), food/beverage (Coca-Cola, PepsiCo), consumer goods
- • Why Learn It: Most job postings specify Allen-Bradley. Training ecosystem is strong (community colleges, Rockwell training centers)
2. Siemens (30% Market Share)
European standard, strong in pharmaceuticals and automotive. Gaining ground in North America. If you know AB + Siemens, you're golden.
- • Programming Software: TIA Portal (Totally Integrated Automation), STEP 7
- • PLC Families: S7-1200 (small), S7-1500 (medium-large), S7-300/400 (legacy but still widely used)
- • Programming Languages: Ladder logic (LAD), structured text (SCL), function block diagram (FBD), statement list (STL)
- • HMI/SCADA: WinCC (HMI/SCADA), WinCC Professional
- • Common Industries: Pharmaceuticals (Pfizer, Merck), automotive (BMW, VW plants in U.S.), packaging
- • Why Learn It: Pharma pays premium. European companies operating in U.S. prefer Siemens
3. Schneider Electric (Modicon) (10% Market Share)
Common in water/wastewater, oil & gas, and infrastructure. Modicon PLCs are workhorses in harsh environments.
- • Programming Software: EcoStruxure Control Expert (formerly Unity Pro), Machine Expert
- • PLC Families: Modicon M580, M340, M241 (Modicon is the PLC brand under Schneider)
- • Programming Languages: Ladder logic, structured text, function block
- • HMI/SCADA: Vijeo Designer (HMI), Citect SCADA
- • Common Industries: Water/wastewater treatment, oil & gas, mining, energy management
- • Why Learn It: Infrastructure projects (smart grids, water systems) often use Schneider
4. Mitsubishi Electric (8% Market Share)
Japanese PLC platform, common in robotics and packaging. Excellent for motion control and high-speed applications.
- • Programming Software: GX Works3, GX Works2
- • PLC Families: FX5 (micro), iQ-R (modular), iQ-F (compact)
- • Programming Languages: Ladder logic, structured text, sequential function chart
- • HMI: GT Designer (GOT HMIs)
- • Common Industries: Packaging machinery, robotics, automotive tier-1 suppliers
- • Why Learn It: Japanese companies (Toyota, Honda suppliers) use Mitsubishi. Excellent motion control capabilities
5. Omron (5% Market Share)
Another Japanese platform, strong in medical devices and precision manufacturing.
- • Programming Software: Sysmac Studio
- • PLC Families: NX/NJ series (high-performance), CP series (compact)
- • Programming Languages: Ladder logic, structured text, motion control languages
- • HMI: Sysmac Studio HMI, NA-series HMIs
- • Common Industries: Medical device manufacturing, semiconductor equipment, inspection systems
- • Why Learn It: Medical device sector pays well and values precision control
🎯 Career Strategy: Which PLCs Should You Learn?
Recommended learning path for maximum employability:
- • Year 1-2: Master Allen-Bradley (Studio 5000). This gets you 70% of job opportunities
- • Year 2-3: Add Siemens (TIA Portal). Now you cover 90% of North American jobs
- • Year 3+: Pick up Schneider, Mitsubishi, or Omron based on your industry specialization
- • Advanced: Learn HMI/SCADA (FactoryTalk View, WinCC, Ignition), robotics integration, motion control
Note: Once you master one PLC platform deeply, learning others is relatively easy—the underlying logic concepts (timers, counters, Boolean logic, sequencing) are universal. The syntax changes but the thinking doesn't.
Beyond PLCs: Related Technologies You'll Work With
Controls technicians don't just program PLCs—you integrate entire ecosystems of industrial automation technologies. Here's what else you'll master:
HMI (Human-Machine Interface)
The touchscreen displays that operators use to control machinery. You'll design HMI screens, create operator buttons, display real-time data, and build alarm systems.
- • Software: FactoryTalk View (Rockwell), WinCC (Siemens), Ignition (Inductive Automation), Red Lion Crimson
- • What You'll Do: Create graphical interfaces, trend historical data, configure alarms, design operator navigation
- • Typical Projects: 10-20 HMI screens per production line showing machine status, production counts, error codes
SCADA (Supervisory Control and Data Acquisition)
Plant-wide monitoring and data collection systems. SCADA pulls data from dozens or hundreds of PLCs across a facility to give management a bird's-eye view.
- • Software: FactoryTalk SCADA, WinCC SCADA, Ignition, Wonderware System Platform
- • What You'll Do: Configure data historians, build dashboards, create reports, integrate with MES/ERP systems
- • Typical Projects: Collect OEE data (Overall Equipment Effectiveness), monitor energy consumption, track production KPIs
VFDs (Variable Frequency Drives)
Motor speed controllers. VFDs adjust motor speed for conveyors, pumps, fans, and mixers—and you'll program PLCs to command them.
- • Brands: Allen-Bradley PowerFlex, ABB ACS, Siemens Sinamics, Schneider Altivar
- • What You'll Do: Configure motor parameters, program speed ramps, integrate with PLC via Ethernet/IP or Profinet, troubleshoot faults
- • Typical Applications: Conveyor speed control, pump flow regulation, fan damper control
Industrial Robotics
Collaborative robots (cobots), articulated arms, and delta robots. Controls technicians integrate robots with PLCs for coordinated motion.
- • Brands: FANUC, ABB, KUKA, Universal Robots (UR), Yaskawa Motoman
- • What You'll Do: Program robot teach points, integrate with PLC via digital I/O or Ethernet, coordinate pick-and-place sequences
- • Typical Projects: Palletizing systems, vision-guided picking, assembly line coordination
Industrial Networking
PLCs, HMIs, VFDs, robots, and sensors all communicate over industrial networks. You'll configure switches, troubleshoot network loops, and manage IP addresses.
- • Protocols: Ethernet/IP (Rockwell), Profinet (Siemens), Modbus TCP/IP, OPC UA
- • Hardware: Managed industrial Ethernet switches (Cisco IE, Hirschmann, Moxa)
- • What You'll Do: Configure VLANs, set up device routing, troubleshoot packet loss, manage device firmware updates
Sensors & Instrumentation
The eyes and ears of automation: proximity sensors, photoelectric eyes, vision cameras, temperature transmitters, flow meters, pressure sensors.
- • Brands: Banner Engineering, Sick, Cognex (vision), Keyence, ifm
- • What You'll Do: Mount sensors, wire inputs to PLC, program logic to detect product presence/absence, calibrate analog signals
- • Typical Applications: Part detection, barcode scanning, vision inspection, temperature/pressure monitoring
Career Progression: From Electrician to Automation Engineer
Level 1: Industrial Electrician with Basic PLC Exposure
Years: 0-2 | Salary: $40K - $58K
- • Complete electrical apprenticeship or industrial electrician program (2-4 years)
- • Learn electrical fundamentals: wiring, motor controls, relay logic, panel building, NEC code
- • Get exposed to PLCs by assisting controls technicians: pulling I/O wiring, replacing sensors, downloading PLC programs
- • Take introductory PLC course at community college or manufacturer training center (Allen-Bradley or Siemens)
- • Read ladder logic, understand basic I/O addressing, troubleshoot input/output devices
Level 2: Junior Controls Technician
Years: 2-4 | Salary: $50K - $68K
- • Write simple PLC programs: timers, counters, Boolean logic, basic sequencing
- • Modify existing ladder logic: add new sensor inputs, adjust timer presets, update HMI screens
- • Troubleshoot PLC-controlled systems: use online monitoring, force I/O, diagnose faults
- • Complete intermediate PLC training: data handling, math instructions, subroutines, analog scaling
- • Learn HMI programming: create basic screens, add buttons/indicators, configure alarms
- • Gain experience with one primary PLC platform (usually Allen-Bradley in U.S.)
Level 3: Experienced Controls Technician
Years: 4-7 | Salary: $65K - $85K
- • Program complete production lines from scratch: conveyors, robots, packaging equipment, inspection systems
- • Master 2+ PLC platforms (e.g., Allen-Bradley + Siemens)
- • Design HMI/SCADA systems: multi-screen navigation, data trending, recipe management, user access levels
- • Integrate VFDs, servo motors, vision systems, robotics into PLC programs
- • Commission new equipment: coordinate with OEMs, witness acceptance testing (FAT/SAT), train operators
- • Lead small projects: upgrade PLC hardware, migrate legacy systems, implement safety circuits
- • Mentor junior technicians and electricians
Level 4: Senior Controls Technician / Controls Specialist
Years: 7-12 | Salary: $78K - $98K
- • Design control systems architecture: PLC hardware selection, network topology, I/O distribution, panel layout
- • Program complex automation: batch processing, motion control, multi-axis robotics, machine vision integration
- • Implement safety systems: safety PLCs (GuardLogix, Siemens FailSafe), light curtains, e-stops, safety interlocks
- • Develop standardized code libraries: AOIs (Add-On Instructions), function blocks, templates for reusable logic
- • Lead major capital projects: new production line installations, plant-wide upgrades, greenfield facility startups
- • Interface with IT for MES/ERP integration: OPC servers, SQL databases, cloud connectivity
- • Potential to become plant "Controls Subject Matter Expert"
Level 5: Controls Engineer / Automation Engineer
Years: 10+ (or 4-year engineering degree) | Salary: $85K - $120K+
- • Design control systems from concept: P&IDs, electrical schematics, network diagrams, specifications
- • Manage multi-million-dollar automation projects: budget, timeline, vendor coordination, commissioning
- • Develop control strategies for complex processes: closed-loop PID control, recipe management, batch sequencing, statistical process control
- • Supervise controls technicians and contractors during installations
- • Write functional specifications for equipment purchases (URS, FAT protocols)
- • Some companies require engineering degree (electrical, mechanical, computer) for this title; others promote from senior tech role
- • Advancement options: Engineering Manager, Automation Manager, Controls Engineering Director
🎓 Do You Need a Degree?
No, but it helps for advancement. Here's the reality:
- • Entry to Senior Technician ($50K-$98K): No degree required. Electrician apprenticeship + PLC training + experience gets you there
- • Controls Engineer Title: Some companies require B.S. in Electrical/Mechanical/Computer Engineering. Others promote senior techs without degrees
- • Associate's Degree (AAS) in Automation/Mechatronics: 2-year degree accelerates your path. Community colleges offer excellent programs (Sinclair, Ivy Tech, Gateway)
- • Bachelor's Degree (B.S.E.T. or B.S.E.E.): Opens doors to engineering roles, but you'll compete with career techs who have 10 years of hands-on PLC experience
Bottom line: You can absolutely make $80K-$100K as a senior controls technician without a degree. For $100K+ engineering/management roles, a degree helps but isn't always mandatory.
A Day in the Life: What Controls Technicians Actually Do
Typical Day: Automotive Parts Plant, Experienced Controls Technician
6:00 AM - Production Meeting & Daily Priorities
Arrive at automotive parts plant (stamping and assembly). Daily production meeting with maintenance supervisor, electricians, and mechanics. Line 3 had intermittent stops overnight—robot #4 faulting. Line 5 scheduled for new vision system installation today. Priority: get Line 3 stable, then support Line 5 project.
6:30 AM - Troubleshooting Robot Fault (Line 3)
Pull up FactoryTalk View HMI on laptop. Review alarm history—robot throwing "E-stop fault" intermittently. Go to robot cell, check e-stop circuit wiring. Notice frayed wire at safety relay. Replace wire, test e-stop circuit with multimeter. Clear fault, cycle robot through home routine. Monitor for 30 minutes—no faults. Document repair in CMMS (computerized maintenance management system).
8:00 AM - Line 5 Vision System Installation Kickoff
Meet with project team: mechanical engineer, OEM technician (vision system vendor), production supervisor. New Cognex vision camera will inspect stamped parts for cracks. Task: integrate vision system with existing Allen-Bradley ControlLogix PLC. Camera communicates via Ethernet/IP. Confirm IP address, verify network switch configuration, test ping from PLC. Camera responds—good. Begin PLC programming.
9:00 AM - PLC Programming (Line 5 Vision Integration)
Open Studio 5000 Logix Designer. Add Ethernet/IP module for Cognex camera in I/O tree. Create new program subroutine: "Vision_Inspection_L5". Write ladder logic: When part arrives (proximity sensor true), trigger camera inspection. Camera sends pass/fail bit back to PLC. If fail, divert part to reject bin via pneumatic pusher. If pass, index conveyor to next station. Add interlocks: don't trigger camera if conveyor stopped or upstream station faulted. Download program to PLC, test offline first with simulation.
10:30 AM - HMI Updates (Line 5 Vision Screens)
Update FactoryTalk View HMI. Create new screen: "Line 5 - Vision Inspection". Add camera status indicator (green = good, red = fault). Display pass/fail counts, reject rate percentage. Add reset button for operators to clear counts. Test HMI in runtime mode—buttons work, data updates correctly. Build application and push to production HMI panel.
12:00 PM - Lunch Break
Eat lunch in break room. Chat with electricians about upcoming plant shutdown next month—controls team will upgrade Line 2 PLC from old SLC-500 to CompactLogix (legacy migration project). Plan overtime schedule.
1:00 PM - Vision System Commissioning (Line 5)
OEM technician finishes teaching vision camera (training inspection algorithm with good/bad part samples). Production runs 50 test parts through line. Camera accurately detects 3 cracked parts—reject system works perfectly. One false reject—adjust camera sensitivity with OEM tech. Re-run 50 parts—zero false rejects. System validated. Production supervisor signs off on commissioning checklist.
2:30 PM - Emergency Call: Line 1 Down
Radio call: Line 1 conveyor stopped, not responding to operator controls. Run to Line 1. HMI shows "VFD Fault" for main conveyor drive. Check Allen-Bradley PowerFlex VFD—displaying "Motor Overload" fault. Check motor current draw—30 amps (normal is 15 amps). Something jamming conveyor. Maintenance mechanic finds metal bracket wedged in conveyor rollers. Remove obstruction, reset VFD fault, test conveyor motion. Current drops to 15 amps—normal. Line back in production. Total downtime: 18 minutes.
3:30 PM - PLC Program Documentation
Back at desk. Update PLC program comments for Line 5 vision integration. Export ladder logic to PDF for maintenance records. Update control system drawings: add vision camera to electrical schematic, update network diagram with new Ethernet/IP device. File documentation in plant engineering server.
4:00 PM - Planning Next Week's Projects
Review project queue with controls supervisor. Next week: Install new safety PLC (GuardLogix) on Line 4 press—safety light curtains need integration. Order parts: GuardLogix controller, safety I/O modules, Ethernet cables. Coordinate with electrician to pull new conduit. Schedule production downtime for Saturday installation (overtime pay).
4:30 PM - Wrap-Up
Check Lines 1, 3, 5 one last time—all running smooth. Update shift turnover log for night shift controls tech: Line 5 vision system live, monitor for issues. Line 3 e-stop repair holding steady. Head home. Total OT today: 0.5 hours (30 min past shift to finish VFD troubleshooting).
đź’ˇ What Makes Controls Work Unique
Unlike pure programming jobs (software engineers at desks) or pure trade jobs (electricians pulling wire all day), controls work is a hybrid of mental and physical problem-solving:
- • 40% of your time: Writing code on a laptop (PLC ladder logic, HMI screens, network config)
- • 30% of your time: Hands-on troubleshooting (climbing into machines, tracing wires, replacing sensors, testing circuits)
- • 20% of your time: Coordination and communication (meetings, vendor calls, training operators, documenting)
- • 10% of your time: Planning and design (electrical schematics, network diagrams, project specs)
If you like solving puzzles, working with your hands, and seeing immediate results when your code makes a machine run—this is the career.
How to Get Started: Training Paths and Certifications
Path 1: Electrical Apprenticeship + PLC Training (Most Common)
Best for: High school graduates or career changers who want hands-on training and earn-while-you-learn
- • Step 1: Complete electrical apprenticeship (4-5 years). Union (IBEW) or non-union (IEC, ABC, company-sponsored). Learn electrical fundamentals, motor controls, wiring, NEC code. Earn $15-$25/hr while learning.
- • Step 2: Get licensed electrician credential (Journeyman Electrician in most states). Requires 8,000 hours on-the-job + passing exam.
- • Step 3: Take PLC courses at community college or manufacturer training center (evenings/weekends). Focus on Allen-Bradley first. Cost: $500-$2,000 for intro + intermediate courses.
- • Step 4: Seek controls-focused electrician role at manufacturing plant. Assist controls techs, learn PLC troubleshooting on the job.
- • Timeline: 5-7 years to become experienced controls technician ($65K-$85K)
Path 2: Associate's Degree in Automation/Mechatronics (Faster)
Best for: Motivated learners who want structured curriculum and faster entry to controls roles
- • Degree: AAS in Industrial Automation, Mechatronics, Electrical Engineering Technology, or similar. 2 years, full-time.
- • Curriculum: Electrical theory, motor controls, PLCs (Allen-Bradley, Siemens), HMI/SCADA, robotics, hydraulics/pneumatics, industrial networking.
- • Hands-On Labs: Good programs have PLC trainers, robot cells, conveyor systems for practice. Look for colleges with industry partnerships.
- • Top Schools: Sinclair Community College (OH), Ivy Tech (IN), Gateway Technical College (WI), Hennepin Technical College (MN), many others.
- • Cost: $8K-$20K total (in-state community college tuition)
- • Outcome: Graduate with PLC programming skills, get hired as junior controls technician ($50K-$65K entry). Faster than apprenticeship route.
Path 3: Bachelor's Degree in Engineering (For Engineering Roles)
Best for: Students targeting Controls Engineer / Automation Engineer title from day one
- • Degrees: B.S. in Electrical Engineering, Mechanical Engineering, Computer Engineering, or Electrical Engineering Technology (BSET)
- • Advantages: Start as "Controls Engineer" instead of technician. Faster salary progression. Design authority on projects.
- • Disadvantages: 4 years + $40K-$100K debt. Less hands-on PLC experience than techs who came up through trades. You'll learn theory but need OJT for real-world troubleshooting.
- • Recommendations: Take PLC electives. Do internships/co-ops in manufacturing. Supplement with online PLC courses (Udemy, LinkedIn Learning, PLC Academy).
Manufacturer Certifications (Optional but Valuable)
| Certification | Provider | Cost | Value |
|---|---|---|---|
| Certified Control Systems Technician (CCST) | ISA (International Society of Automation) | $600-$1,000 | Industry-recognized, vendor-neutral |
| Allen-Bradley Certified | Rockwell Automation | $2,000-$5,000 (training + exam) | Valuable if working at AB-heavy plant |
| Siemens Certification (SCC) | Siemens | $1,500-$4,000 | Useful in pharma, European companies |
| Certified Automation Professional (CAP) | ISA | $800-$1,200 | Advanced, for engineers/senior techs |
🎓 My Recommendation: Best ROI Path
For fastest entry with lowest debt and highest earning potential:
- Get 2-year AAS in Industrial Automation from community college with strong industry ties ($8K-$15K total cost)
- Learn Allen-Bradley PLCs deeply during school (Studio 5000, FactoryTalk View, motor controls)
- Do internship/co-op at local manufacturer during 2nd year (paid, gets you OJT + job offer)
- Get hired as junior controls tech at $50K-$65K right out of school
- Work 3-5 years to master troubleshooting, add Siemens to your skillset, become senior tech at $75K-$90K
- Optional: Pursue BSET degree part-time (employer-paid tuition reimbursement) to unlock engineering title
Outcome: Age 24-26, making $75K-$90K, zero or minimal debt, in-demand skills, clear path to $100K+ by age 30.
Top Employers & Industries Hiring Controls Technicians
By Industry
đźš— Automotive Manufacturing
Why #1: Highest automation density. Assembly lines have hundreds of robots, conveyors, vision systems. Pay: $65K-$105K
- • OEMs: GM, Ford, Stellantis (Chrysler), Tesla, BMW, VW, Toyota, Honda
- • Tier 1 Suppliers: Magna, Lear, Adient, BorgWarner, Continental
- • PLC Platform: Primarily Allen-Bradley, some Siemens
🍕 Food & Beverage Processing
Why Popular: Recession-proof (people always eat). Clean environments. Pay: $60K-$90K
- • Companies: Coca-Cola, PepsiCo, Nestle, Kraft Heinz, General Mills, Tyson Foods
- • Focus: Batch processing, recipe management, CIP (clean-in-place) systems, FDA compliance
- • PLC Platform: Allen-Bradley, Siemens, Schneider
đź’Š Pharmaceuticals & Medical Devices
Why High-Paying: FDA validation requirements. Precision controls. Pay: $70K-$110K
- • Companies: Pfizer, Merck, Johnson & Johnson, Abbott, Medtronic, Stryker
- • Focus: GMP compliance, batch tracking, 21 CFR Part 11 (electronic signatures), clean rooms
- • PLC Platform: Siemens dominant, Allen-Bradley also common
📦 Packaging & Material Handling
Why Growing: E-commerce boom = warehouse automation. Pay: $58K-$85K
- • Companies: Amazon (fulfillment centers), UPS, FedEx, ProMach (packaging OEM)
- • Focus: Conveyor systems, sortation, palletizing robots, AGVs, WMS integration
- • PLC Platform: Allen-Bradley, Siemens, Mitsubishi
⚡ Oil & Gas / Petrochemical
Why High-Paying: Hazardous locations, complex processes. Pay: $75K-$115K
- • Companies: ExxonMobil, Chevron, Shell, Dow Chemical, BASF
- • Focus: DCS (Distributed Control Systems), safety instrumented systems (SIS), HAZLOC wiring
- • PLC Platform: Allen-Bradley, Siemens, Schneider, Honeywell DCS
🏠System Integrators (SIs)
Why Exciting: Work on diverse projects. Travel nationwide. Pay: $65K-$100K + per diem
- • Companies: Concept Systems, Hallam-ICS, Automated Control Concepts, EPS Corporation
- • Focus: Custom automation projects for end users. Machine builders. Retrofits and upgrades.
- • Lifestyle: 50-75% travel common. Project-based work. Variety of industries.
Top Metro Areas for Controls Jobs
- • Detroit, MI / Midwest Auto Corridor: Highest density of automotive automation jobs (MI, OH, IN, IL)
- • Houston / Gulf Coast, TX: Petrochemical, oil & gas, energy sector controls
- • Greenville / Spartanburg, SC: BMW, Michelin, auto suppliers, advanced manufacturing hub
- • Los Angeles / Orange County, CA: Aerospace, food processing, packaging, medical devices
- • Milwaukee / Chicago, IL: Diverse manufacturing, food processing, brewing, packaging
- • Charlotte, NC: Food processing (Nestle, Coca-Cola), pharmaceuticals, automotive
- • Phoenix, AZ: Semiconductor, aerospace, data centers (emerging)
Pros & Cons of Controls Technician Careers
âś… Pros
- âś“Tech + Trades Hybrid: Use your brain (programming, logic) AND your hands (troubleshooting, wiring). Not stuck at a desk all day
- âś“Excellent Pay: $65K-$100K with no bachelor's degree. Overtime pushes total comp to $100K+
- âś“Massive Shortage: Manufacturers desperate for controls talent. Job security for decades
- âś“Immediate Impact: Your code makes machines run. Tangible results daily (unlike abstract software dev)
- ✓Variety: Every day different—troubleshooting, programming, commissioning, training. Not repetitive
- ✓Clear Advancement Path: Electrician → Controls Tech → Senior Tech → Engineer → Manager
- âś“Transferable Skills: PLC programming works in ANY industry with automation (food, auto, pharma, energy)
❌ Cons
- âś—High Pressure: Production line down = lose $10K-$50K per hour. Pressure to fix NOW. Emergency calls at 2 AM
- âś—Steep Learning Curve: Must understand electrical AND programming AND mechanical systems. Takes years to master
- âś—Physically Demanding: Climb inside machines, work in tight spaces, stand for hours, exposure to noise/heat/cold
- âś—Proprietary Platforms: Allen-Bradley skills don't fully transfer to Siemens. Always learning new platforms
- âś—Weekend/Night Work: Programming and commissioning done during non-production hours. Shift differentials help but work-life balance suffers
- âś—Travel (SI Roles): System integrator jobs involve 50-75% travel. Great when you're young, tough with family
- âś—Manufacturing Cycles: Plants close, production moves overseas, automation companies downsize during recessions
Frequently Asked Questions
Can I learn PLCs without an electrical background?
Technically yes, but it's harder. PLC programming logic (Boolean logic, timers, counters) can be learned by anyone with decent math skills. HOWEVER, controls technicians must also troubleshoot electrical circuits, read schematics, understand motor controls, and diagnose sensor failures. Most successful controls techs have electrical apprenticeship or AAS degree background. If you're starting from zero, get an AAS in Industrial Automation—it covers both electrical AND PLC programming.
Is PLC programming similar to software programming (Python, C++)?
Somewhat, but different philosophy. PLC ladder logic mimics electrical relay logic—it's visual (ladder rungs) rather than text-based. You're controlling physical hardware (motors, valves, conveyors) not building apps. Structured text (ST) in PLCs is closer to Pascal/BASIC. If you know software dev, PLC logic will feel simplistic initially, but the challenge is integrating with real-world I/O, timing constraints, and safety-critical applications. Software devs can transition to controls, but must learn electrical fundamentals and industrial environments.
What's the difference between Controls Technician and Controls Engineer?
Mainly title, credential, and scope—not always skill level. Controls Technician: Electrician background, hands-on focus, programs and troubleshoots existing systems. Controls Engineer: Engineering degree (BSEE, BSME, BSET), designs control systems from scratch, writes specs, manages projects. In practice, senior controls technicians (10+ years) often do the same work as engineers but lack the title. Some companies promote techs to "engineer" without degree; others require BSEE. Pay overlaps significantly ($80K-$100K range for both senior tech and junior engineer).
Can I work remotely as a controls technician?
Rarely for technician roles, sometimes for engineering roles. Controls work is hands-on—you must be on the factory floor to troubleshoot machinery, wire I/O, commission equipment. However, some aspects CAN be remote: PLC programming (write code at home, upload to PLC remotely via VPN), HMI design, documentation, project planning. System integrators sometimes allow senior engineers to work remotely 2-3 days/week. But if you want 100% remote, pursue software/IT roles, not industrial controls.
Is AI going to replace controls technicians?
No—AI will change the work, not eliminate it. AI can optimize PLC programs, suggest logic improvements, predict equipment failures. But AI cannot climb into a conveyor to replace a broken sensor, diagnose why a robot's gripper is jamming, or commission a new production line on a factory floor. Controls is a physical + digital hybrid job—the physical troubleshooting aspect is robot-proof. If anything, AI tools will make controls techs MORE productive (faster commissioning, better diagnostics). The techs who embrace AI augmentation will thrive.
Should I specialize in one industry or stay generalist?
Start generalist, specialize later for higher pay. Early career (first 5 years): work in different industries (food, auto, packaging) to learn diverse PLC applications and platforms. Mid-career (5-10 years): specialize in high-paying industry (pharma, oil & gas, aerospace) or technology (robotics, motion control, vision systems). Specialists earn $10K-$20K more than generalists. Examples: Pharmaceutical controls tech with FDA validation experience commands premium. Robotics integration specialist earns more than general conveyor programmer.
Final Thoughts: Is Electrical Controls Right for You?
Electrical controls is the perfect career for people who want to program robots without sitting at a desk all day. You'll earn $65K-$100K, solve complex problems, work with cutting-edge automation technology, and see your code bring multi-million-dollar production lines to life.
It's not easy—you need electrical fundamentals, programming logic, mechanical understanding, troubleshooting skills, and the ability to work under pressure when production lines go down. But if you're someone who:
- • Likes solving puzzles and figuring out how things work
- • Enjoys both mental challenges (coding) and physical work (climbing into machines)
- • Wants immediate, tangible results (not abstract software)
- • Values job security and excellent pay without needing a 4-year degree
- • Can handle pressure and thinks clearly during emergencies
...then electrical controls technician might be the best career decision you ever make. The shortage is real, the pay is excellent, and manufacturers are begging for qualified people. The robots need you. Get started today.