Controls Engineer Salary Overview
A Controls Engineer in the United States earns a median of $96,800 a year, or about $46.54 an hour over a full-time year of 2,080 hours. The role requires proficiency with industry-standard tools and technologies including PLC programming (RSLogix 5000/Studio 5000, TIA Portal), HMI/SCADA (FactoryTalk, Ignition, WonderWare), MATLAB/Simulink, Python, ladder logic, function block diagrams, DCS systems, industrial networking (EtherNet/IP, PROFINET). The band runs from $57,000 to $148,400, a spread of 160 per cent between the two ends, which for this occupation is decided mainly by years in the role and by the employer rather than by job title. On the median salary, federal income tax takes about $12,910 and FICA another $7,405, leaving $76,485 in a state with no income tax such as Texas or Florida; add California income tax of roughly $5,140 and take-home pay falls to about $71,345, an effective rate of 26.3 per cent. Education: The typical path to becoming a Controls Engineer involves earning a Bachelor's in Electrical Engineering, Mechanical Engineering, or Controls/Automation Engineering; Master's for advanced control theory or robotics applications.
From entry to lead, pay for a Controls Engineer roughly 2.2-doubles, running from $63,888 to $138,424. That is the ordinary shape for a skilled occupation: enough room that experience is paid for, not enough that a late start is unrecoverable. The useful comparison when weighing an offer is therefore not against the median but against the band for the level being offered.
The largest single step is the one out of the entry level, worth about $32,912 a year. That places the decisive moment early: the two or three years it takes to stop being junior are worth more than any later promotion, which argues for choosing a first employer on what it will teach rather than on what it pays.
The best-paying states for this occupation are split: TX levies no income tax at all while CA, MI does, so two gross offers that look alike do not end alike. On this median salary the state layer alone is worth several thousand dollars a year, which is why the table below ranks by take-home pay rather than by gross.
Demand concentrates in San Jose, CA, Detroit, MI, Houston, TX, and those are also among the most expensive places to live in the country. A premium of ten or twenty per cent on the median does not survive a housing cost twice the national figure, so the right comparison for a Controls Engineer weighing a move is take-home pay minus rent, not salary against salary.
The Controls Engineer is one of the most important roles in the Engineering sector of the US economy in 2026. With a median annual salary of $96,800, compensation for this position ranges from $57,000 at the entry level to $148,400 for highly experienced professionals in top-paying markets.
This career typically requires Bachelor's in Electrical Engineering, Mechanical Engineering, or Controls/Automation Engineering; Master's for advanced control theory or robotics applications. Valued professional credentials include Certified Automation Professional (CAP), PLC vendor certifications (Rockwell/Allen-Bradley, Siemens), ISA certifications, TÜV Functional Safety Engineer. On a day-to-day basis, professionals in this role focus on programming PLCs and HMIs for industrial automation, designing control system architectures, commissioning and starting up automated equipment, troubleshooting production line issues, integrating robots and vision systems, developing SCADA and data historian systems, and managing control system cybersecurity.
The job market for this position shows 8% from 2022-2032 driven by Industry 4.0 automation, smart manufacturing, building automation, and process industry modernization growth, with demand strongest in specializations including PLC/SCADA programming, motion control and robotics, process control (DCS), building automation systems, batch control, and functional safety (SIS/SIL). AI augments controls with predictive algorithms and self-tuning loops, but the system design, safety-critical programming, commissioning troubleshooting, and equipment integration require experienced human controls engineers
Salary Range: The typical Controls Engineer in the US earns between $57,000 and $148,400 per year, with a median of $96,800.
What Does a Controls Engineer Do?
A Controls Engineer spends their workday programming PLCs and HMIs for industrial automation, designing control system architectures, commissioning and starting up automated equipment, troubleshooting production line issues, integrating robots and vision systems, developing SCADA and data historian systems, and managing control system cybersecurity. The role requires proficiency with industry-standard tools and technologies including PLC programming (RSLogix 5000/Studio 5000, TIA Portal), HMI/SCADA (FactoryTalk, Ignition, WonderWare), MATLAB/Simulink, Python, ladder logic, function block diagrams, DCS systems, industrial networking (EtherNet/IP, PROFINET).
The typical work environment involves manufacturing plants, system integrator offices, or traveling to client sites for commissioning; hands-on work on production equipment; some overnight and weekend work during plant shutdowns; combination of office programming and floor commissioning. Within the profession, you can specialize in areas such as PLC/SCADA programming, motion control and robotics, process control (DCS), building automation systems, batch control, and functional safety (SIS/SIL), each requiring different skill sets and offering different compensation levels.
Day-to-day responsibilities vary based on seniority and organization size. Entry-level professionals often focus on execution tasks under supervision, while senior professionals take on strategic planning, mentoring, and cross-functional leadership.
Controls Engineer Salary by Experience
| Level | Salary | Hourly | Take-Home |
|---|---|---|---|
| Entry | $63,888 | $31/hr | $51,122 |
| Mid | $96,800 | $47/hr | $71,345 |
| Senior | $121,000 | $58/hr | $86,066 |
| Lead | $138,424 | $67/hr | $96,355 |
Best and Worst States for Controls Engineer Pay
Which states let a Controls Engineer keep the most, and least, of their salary, ranked by annual take-home pay.
Geographic location significantly impacts Controls Engineer compensation. The top-paying states for this role include Michigan (automotive automation), Ohio (manufacturing), Wisconsin (paper/food processing), Texas (process industries), Indiana (pharmaceutical manufacturing).
States with no income tax (Texas, Florida, Washington, Nevada, Tennessee) offer an effective pay boost of 3-9% compared to high-tax states like California or New York, though these states often compensate with higher cost of living or property taxes. When evaluating offers, consider both gross salary and after-tax take-home pay.
Geographic location creates dramatic differences in Controls Engineer take-home pay. On the same $96,800 salary, the gap between the highest and lowest take-home states spans $5,140 annually. Texas offers the best net income at $76,485, while California results in the lowest at $71,345. This $5,140 difference represents real purchasing power that compounds year over year.
Cost-of-Living Adjusted Analysis: When factoring in regional cost of living, Texas offers the best purchasing power for a Controls Engineer salary. While high-tax states like California and New York offer robust Engineering job markets, their combined tax burden and cost of living can reduce effective purchasing power by 25-40% compared to states like Texas or Georgia. A Controls Engineer earning $96,800 in Texas enjoys purchasing power equivalent to approximately $82,242 in a baseline cost area.
Engineering Hub Analysis: Controls Engineer professionals find the strongest markets in Houston (energy), Detroit (automotive), Seattle (aerospace), and California (defense/tech). Prevailing wage requirements on government-funded projects can add 20-40% to compensation in high-cost areas. For Controls Engineer roles specifically, states investing heavily in infrastructure (Texas, Florida, Georgia) offer growing demand with favorable tax treatment compared to traditional engineering hubs like California or New York.
Top 10 Best States for Controls Engineer Salary
| # | State | Gross | Federal | State Tax | FICA | Take-Home | Rate |
|---|---|---|---|---|---|---|---|
| 1 | Alaska | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 2 | Florida | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 3 | Nevada | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 4 | New Hampshire | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 5 | South Dakota | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 6 | Tennessee | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 7 | Texas | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 8 | Washington | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 9 | Wyoming | $96,800 | $12,910 | $0 | $7,405 | $76,485 | 21.0% |
| 10 | North Dakota | $96,800 | $12,910 | $1,603 | $7,405 | $74,882 | 22.6% |
Bottom 10 Worst States for Controls Engineer Salary
| # | State | Gross | Federal | State Tax | FICA | Take-Home | Rate |
|---|---|---|---|---|---|---|---|
| 42 | Kansas | $96,800 | $12,910 | $4,861 | $7,405 | $71,624 | 26.0% |
| 43 | New York | $96,800 | $12,910 | $5,014 | $7,405 | $71,471 | 26.2% |
| 44 | Virginia | $96,800 | $12,910 | $5,050 | $7,405 | $71,435 | 26.2% |
| 45 | Minnesota | $96,800 | $12,910 | $5,132 | $7,405 | $71,353 | 26.3% |
| 46 | California | $96,800 | $12,910 | $5,140 | $7,405 | $71,345 | 26.3% |
| 47 | Delaware | $96,800 | $12,910 | $5,158 | $7,405 | $71,327 | 26.3% |
| 48 | Maine | $96,800 | $12,910 | $5,383 | $7,405 | $71,101 | 26.5% |
| 49 | District of Columbia | $96,800 | $12,910 | $5,387 | $7,405 | $71,098 | 26.6% |
| 50 | Hawaii | $96,800 | $12,910 | $7,058 | $7,405 | $69,427 | 28.3% |
| 51 | Oregon | $96,800 | $12,910 | $7,945 | $7,405 | $68,540 | 29.2% |
Controls Engineer Take-Home Pay by City
Detroit for automotive controls; Milwaukee for food and paper industry automation; Houston for process control; Indianapolis for pharmaceutical automation
When comparing city compensation, factor in cost of living differences. A $96,800 salary in a mid-cost city often provides more purchasing power than a 20-30% premium in San Francisco or New York.
How to turn these figures into an actual offer, what to ask for besides base pay and when to name a number, is covered in the guide to negotiating a salary offer.
| City | Gross Salary | Total Tax | Take-Home | Rate |
|---|---|---|---|---|
| San Jose, CA | $96,800 | $25,455 | $71,345 | 26.3% |
| Detroit, MI | $96,800 | $24,191 | $72,609 | 25.0% |
| Houston, TX | $96,800 | $20,315 | $76,485 | 21.0% |
| Seattle, WA | $96,800 | $20,315 | $76,485 | 21.0% |
| Hartford, CT | $96,800 | $24,889 | $71,911 | 25.7% |
Calculate Controls Engineer Take-Home Pay
Adjust the state and filing status to see your estimated after-tax income.
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Tax Breakdown
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Pay Frequency Breakdown
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How to Become a Controls Engineer
Education: The typical path to becoming a Controls Engineer involves earning a Bachelor's in Electrical Engineering, Mechanical Engineering, or Controls/Automation Engineering; Master's for advanced control theory or robotics applications. Some professionals enter the field through alternative pathways, but formal education provides the strongest foundation for long-term career growth.
Certifications: Key professional credentials for this role include Certified Automation Professional (CAP), PLC vendor certifications (Rockwell/Allen-Bradley, Siemens), ISA certifications, TÜV Functional Safety Engineer. These certifications demonstrate expertise to employers and often directly correlate with higher compensation.
Skills & Tools: Proficiency with PLC programming (RSLogix 5000/Studio 5000, TIA Portal), HMI/SCADA (FactoryTalk, Ignition, WonderWare), MATLAB/Simulink, Python, ladder logic, function block diagrams, DCS systems, industrial networking (EtherNet/IP, PROFINET) is expected for competitive candidates. Building a portfolio of work or gaining practical experience through internships, projects, or entry-level positions is essential for breaking into the field.
Timeline: Most professionals reach mid-level competency within 3-5 years of entering the field, with senior positions typically requiring 7-12 years of progressive experience.
Controls Engineer Career Outlook
Employment for the Controls Engineer role is projected to grow 8% from 2022-2032 driven by Industry 4.0 automation, smart manufacturing, building automation, and process industry modernization, reflecting strong demand driven by industry evolution and changing workforce needs. The most in-demand specializations include PLC/SCADA programming, motion control and robotics, process control (DCS), building automation systems, batch control, and functional safety (SIS/SIL).
AI and Automation Impact: AI augments controls with predictive algorithms and self-tuning loops, but the system design, safety-critical programming, commissioning troubleshooting, and equipment integration require experienced human controls engineers
Professionals who combine deep technical expertise with strong communication skills and adaptability will find the best opportunities in this evolving landscape.
The Controls Engineer sits in the middle of its adjacent group. Robotics Engineer pays $118,400, $21,600 more, while Mechanical Engineer pays $96,310, $490 less, against this role's $96,800. A position in the middle is the most flexible one: it means both directions are open, and that the decision rests on what the work is rather than on what the next title pays, since the difference in either direction is a matter of thousands and not of multiples.
After tax the picture compresses. In California, this role's median leaves about $71,345, and across the whole adjacent group the spread between the highest and lowest take-home figure is $13,485 a year. That compression is the progressive schedule at work: a gross gap of ten thousand dollars between two neighbouring occupations is worth appreciably less once the marginal rate has taken its share, which is why a move made for the salary alone disappoints more often than the gross figures suggest.
Tax Tips for Controls Engineer Earnings
The strategies that apply to every salaried professional, the contribution limits, the bracket arithmetic and the question of moving to a state without an income tax, are set out once in the guide to tax strategies for salaried professionals rather than repeated on each occupation page.
Controls Engineer Salary FAQ
The median annual salary for a Controls Engineer in the United States is $96,800 in 2026. Compensation typically ranges from $57,000 for entry-level positions to $148,400 for experienced professionals in top-paying markets. Actual pay depends on experience, location, certifications, and employer size. On a median salary of $96,800, take-home pay works out to about $71,345 a year before state-specific credits.
On a $96,800 salary, a Controls Engineer takes home approximately $85,000-$105,000 after federal, state, and FICA taxes, depending on the state and filing status. In no-income-tax states like Texas or Florida, take-home pay is higher than in states like California or New York. On a median salary of $96,800, take-home pay works out to about $71,345 a year before state-specific credits.
Entry-level Controls Engineer professionals with 0-2 years of experience can expect to earn around $63,888 per year. Starting salaries vary significantly by location, with major metro areas offering 15-30% premiums over rural areas. On a median salary of $96,800, take-home pay works out to about $71,345 a year before state-specific credits.
The highest-paying states for Controls Engineer professionals include CA, MI, TX. However, when adjusted for cost of living, some mid-tier states offer better purchasing power. No-income-tax states provide an additional 3-9% effective pay boost. On a median salary of $96,800, take-home pay works out to about $71,345 a year before state-specific credits.
The median hourly equivalent for a Controls Engineer is approximately $46.54, based on 2,080 working hours per year. Actual hourly rates vary by experience level, with senior professionals earning $10-30 more per hour than entry-level. On a median salary of $96,800, take-home pay works out to about $71,345 a year before state-specific credits.
To become a Controls Engineer, you typically need Bachelor's in Electrical Engineering, Mechanical Engineering, or Controls/Automation Engineering; Master's for advanced control theory or robotics applications. Valuable certifications include Certified Automation Professional (CAP), PLC vendor certifications (Rockwell/Allen-Bradley, Siemens), ISA certifications, TÜV Functional Safety Engineer. Most employers also value practical experience gained through internships or entry-level positions.
Employment for Controls Engineer professionals is projected to grow 8% from 2022-2032 driven by Industry 4.0 automation, smart manufacturing, building automation, and process industry modernization. AI augments controls with predictive algorithms and self-tuning loops, but the system design, safety-critical programming, commissioning troubleshooting, and equipment integration require experienced human controls engineers. The strongest opportunities are in PLC/SCADA programming, motion control and robotics, process control (DCS), building automation systems, batch control, and functional safety (SIS/SIL).
A Controls Engineer typically spends their day programming PLCs and HMIs for industrial automation, designing control system architectures, commissioning and starting up automated equipment, troubleshooting production line issues, integrating robots and vision systems, developing SCADA and data historian systems, and managing control system cybersecurity. The work environment involves manufacturing plants, system integrator offices, or traveling to client sites for commissioning; hands-on work on production equipment; some overnight and weekend work during plant shutdowns; combination of office programming and floor commissioning.
Personal finance and taxation expert. Specialized in US federal and state tax calculations, paycheck analysis, and helping Americans understand their take-home pay across all 50 states.
Sources & References
Tax rates, salary data, and deduction figures used on this page are sourced from official US government publications:
- IRS.gov, Federal income tax brackets, standard deductions, and tax procedures for the 2026 tax year
- Bureau of Labor Statistics (BLS.gov), Occupational Employment and Wage Statistics (OEWS) for median salary data
- Social Security Administration (SSA.gov), Social Security wage base, FICA tax rates, and Medicare thresholds
- IRS Tax Withholding Estimator, Federal paycheck withholding calculations and verification
Last reviewed and updated: 2026-09-27. This content is for informational purposes only and does not constitute tax advice.