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Automation Engineer
Automation EngineerPrevalent Group • Saint Charles, IL, United States
Automation Engineer

Automation Engineer

Prevalent Group • Saint Charles, IL, United States
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Automation Engineer – Industrial Label Application Systems

Position Summary

The Automation Engineer is responsible for the design, development, and optimization of industrial label application systems used in manufacturing, packaging, and logistics environments. This role involves full lifecycle engineering from concept development through production release, including mechanical design, prototype building, testing, and continuous improvement of labeling machinery and automated systems.

Key Responsibilities

System Design & Development

  • Design complete label application systems including applicator heads, conveyors, mounting frames, guarding, and product handling mechanisms.
  • Develop 3D models and detailed fabrication drawings using SolidWorks or equivalent CAD software, ensuring designs meet functional, safety, and manufacturability requirements.
  • Engineer precision mechanisms for label dispensing, including peel plates, tamp pads, air-blow systems, and wipe-on applicators tailored to specific substrate and label combinations.
  • Design pneumatic and servo-driven motion systems for accurate label placement across varying line speeds and product geometries.
  • Create custom fixturing and tooling for unique product shapes, ensuring consistent label registration and adhesion.
  • Apply Design for Manufacturing (DFM) principles to optimize designs for ease of fabrication, assembly, and cost-effectiveness, considering available manufacturing processes and standard component availability.

Integration & Automation

  • Collaborate with electrical and controls engineers to integrate mechanical systems with PLCs, HMIs, sensors, and vision systems.
  • Specify and select sensors, actuators, motors, and drives appropriate for labeling applications, considering speed, accuracy, and environmental factors.
  • Design systems for seamless integration into existing production lines, accounting for spatial constraints, upstream / downstream equipment, and operator access.
  • Develop modular and scalable designs that accommodate multiple label formats, print engines, and application methods.

    • Prototyping & Testing

  • Build and assemble prototype systems, working hands-on in the shop to validate design concepts and identify improvements.
  • Conduct rigorous testing to verify label placement accuracy, adhesion quality, system reliability, and throughput performance.
  • Analyze test data, identify root causes of failures, and implement design modifications to resolve issues.
  • Perform tolerance stack-up analysis and FEA simulations to ensure mechanical integrity and precision.

    • Project Execution

  • Manage mechanical engineering deliverables within project timelines, coordinating with project managers on milestones and resource requirements.
  • Generate bills of materials (BOMs), coordinate with purchasing on component sourcing, and support production during system builds.
  • Create and maintain technical documentation including assembly procedures, adjustment guides, and maintenance manuals.
  • Participate in design reviews, FMEA sessions, and customer acceptance testing.

    • Continuous Improvement & Support

  • Provide technical support for field installations, troubleshooting mechanical issues and recommending solutions.
  • Analyze field performance data and customer feedback to drive product improvements and standardization.
  • Research new technologies, materials, and manufacturing methods to enhance system performance and reduce costs.
  • Develop and maintain standard component libraries and design templates to improve engineering efficiency.

    • Required Qualifications

  • Bachelor's degree in Mechanical Engineering or related discipline.
  • 3+ years of experience in mechanical design for automated machinery, packaging equipment, or material handling systems.
  • Proficiency in 3D CAD software (SolidWorks preferred) including sheet metal, weldments, and assembly modeling.
  • Strong understanding of GD&T, mechanical tolerancing, and manufacturing processes (machining, fabrication, welding).
  • Experience with pneumatic system design including cylinder sizing, valve selection, and circuit layout.
  • Hands-on prototyping and assembly skills with ability to work effectively in a shop environment.
  • Excellent problem-solving abilities and analytical thinking.

    • Preferred Qualifications

  • Direct experience with label applicators, print-and-apply systems, or pressure-sensitive labeling technology.
  • Knowledge of servo motion systems, timing belt drives, and linear motion components.
  • Familiarity with conveyor design, product handling, and line integration.
  • Experience with FEA software for structural and thermal analysis.
  • Understanding of machine safety standards (OSHA, ANSI, CE marking requirements).
  • Background in food, beverage, pharmaceutical, or consumer goods packaging industries.

    • Work Environment

  • Split time between office / CAD work and hands-on activities in the assembly and test areas.
  • Occasional travel to customer sites for installations, commissioning, and technical support (up to 15%).
  • Collaborative team environment working closely with electrical, software, and production personnel.

    • Physical Requirements

  • Ability to lift up to 50 pounds and work with hand and power tools.
  • Comfortable standing for extended periods during assembly and testing activities.
  • Visual acuity for detailed inspection of mechanical components and label placement quality.
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