Controls & Automation Engineer
Riverside Engineering
Overview
This is where it all started. Riverside Engineering, headquartered in San Antonio, TX, is a leader in the metal recycling industry — built on 40+ years of experience designing and manufacturing Megashredders®, downstream separation systems, and advanced automation platforms. As a member of a 4-person team, I co-invented the first truly non-derivative cruise control system for car shredders and their entire downstream processes. We took throughput from 80 tons/hour to over 200 — fully automated and self-learning. I was recognized as an expert in my field by both the Canadian and US governments, and co-authored two industry papers.
Key Achievements
Invented Non-Derivative Cruise Control System
Member of a 4-person team that invented and commissioned the first truly non-derivative cruise control system for car shredders and their downstreams — including ferrous/non-ferrous separation, color and size sorting, content analysis, and throughput optimization. Fully automated and self-learning.
80 → 200+ Tons/Hour
The cruise control system multiplied throughput from 80 tons/hour to over 200 tons/hour — a transformational leap in productivity. Integrated thousands of input/output signals and controlled hundreds of motors across the entire yard.
Recognized Government Expert
Recognized as an expert in the field by both the Canadian and US governments. Co-authored two industry papers on shredder automation and controls systems.
Legacy Software Conversion
Devised a method to convert old software tags into modern ones, cutting conversion time from weeks down to hours — enabling rapid modernization of legacy shredder control systems.
3D Yard Visualization
Learned 3D design to build accurate digital models of actual yard equipment in their correct physical layout. This enabled remote troubleshooting and gave employees an intuitive navigation system for understanding complex recycling yards.
Megashredder® Controls Systems
Designed complete controls architectures for Riverside's M-Series Megashredders (M-69, M-88, M-106, M-122) — from I/O layouts and panel designs to full PLC programs controlling shredders, conveyors, separators, and downstream sorting equipment.
PLC Programming (RSLogix 5000)
Wrote and debugged ladder logic, structured text, and function blocks for Allen-Bradley ControlLogix and CompactLogix platforms. Integrated thousands of I/O signals controlling hundreds of motors, safety interlocks, production data logging, and yard automation.
Challenges & Solutions
Metal recycling is brutal on equipment
Designed controls with robust fault handling, redundant sensors, and degraded-mode operation. When a shredder jams at 3 AM, the system needs to protect itself and give the operator a clear path to recovery.
Legacy systems and integration
Often worked with existing equipment that had outdated controls. Developed approaches to integrate modern PLCs with legacy motor starters, relay logic, and mechanical interlocks without tearing everything out.
Commissioning under pressure
Plant downtime costs thousands per hour. Learned to prepare meticulously, test systematically, and stay calm when things don't work the first time — because they rarely do.
Processes Implemented
01Systematic Commissioning
Developed a methodical approach to startup: verify I/O point-by-point, test each device individually, run subsystems in isolation, then integrate step by step. This approach catches problems early when they're cheap to fix.
02Controls Documentation
Created comprehensive documentation packages — wiring diagrams, I/O lists, PLC program descriptions, and operator manuals. Good documentation is what separates a professional installation from a hack job.
03Alarm Management
Designed alarm systems that prioritize critical faults, suppress nuisance alarms, and give operators actionable information instead of a wall of red lights.
04Yard Automation
Developed automation systems to electronically monitor and maximize recycling yard capabilities — integrating shredder controls with downstream separation equipment, material handling, and production tracking for full-yard visibility.
Lessons Learned
“I was fortunate to have incredible mentors at Riverside — people who shaped not just my engineering skills, but my character. Those mentoring relationships continue to this day.”
“Leave things better than you found them. Every panel, every program, every system — if you touched it, it should be better when you walk away.”
“Take pride in your work, especially when nobody is looking. Because someone eventually will take notice. Quality speaks for itself, and people remember who built it right.”
“Follow through with your commitments. In controls engineering, a half-finished program is worse than no program at all. The same is true in business and in life.”
“First-principles problem solving and fast-thinking troubleshooting are the most transferable skills I've ever developed. They apply to everything — engineering, sales, business building.”
“Riverside eventually recognized that I had sales skills, which gave me the confidence to start 2M Electrical Representatives. Sometimes it takes someone else seeing your potential before you see it yourself.”
“Understanding the politics of business and what it actually takes to be successful — not just technically, but organizationally — was just as valuable as any engineering skill I learned.”
“When your shredder uses 1,000-pound hammers and processes 200+ tons per hour, there is zero tolerance for controls failures. This environment teaches you to build systems that survive the worst day, not just the average day.”
Gallery
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Controls panel designed and built for a recycling facility
Controls panel designed and built for a recycling facility
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Metal recycling facility — factory floor
Metal recycling facility — factory floor
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Allen-Bradley ControlLogix PLC rack
Allen-Bradley ControlLogix PLC rack
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HMI operator interface
HMI operator interface
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On-site commissioning and startup
On-site commissioning and startup