AUTOMATIC BOTTLE FILLING, CAPPING AND LABELLING SYSTEM

Project Title

AUTOMATIC BOTTLE FILLING, CAPPING AND LABELLING SYSTEM

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

We will develop a system for a bottle filling, capping and labelling machine using Programmable Logic Controller (PLC) based controller for automation industry. The main aim of the project is to design and fabricate a small and a simple system using PLC. The belt conveyor will be used for moving the bottle and a DC pump will be set on tank to control the flow of water. The position of bottle will be detected by proximity sensor so that pump can be function at right time. When bottles are under the tank, the pump will be started and bottle will be filled by liquid after which capping of the bottle takes place using piston rotation system and then labelling of the bottles will be performed. This machine proposed  will be cost effective and it can be used in small scale bottle filling industries such as coffee shops, juice shops and other beverage industries.

Project Objectives

The objective of our project is to design, develop and monitor “Automatic bottle filling system using PLC”. This proposed system will have many benefits such as low power consumption, low operational cost, less maintenance and high accuracy . This project is based on Industrial automation and is a vast application used in many industries like milk industries, chemical, food, mineral water and bottle filling industries. A working prototype will be developed for demonstration purpose.

Project Implementation Method

The project is based on industrial automation and PLC is the brain of this automation system . The hardware and the software are the two important areas in our project.

HARDWARE DESCRIPTION:

 In this project, Siemens PLC SIMATICS S7 1200 is used for controlling the inputs and outputs. Input supply to the PLC is given through a SMPS. The rating of the SMPS is 24V DC 5Amps. The PLC used here is a compact PLC which has fixed number of inputs and outputs. The PLC, CPU contains 14 digital inputs and 10 digital outputs. One diffused photoelectric sensor will be used for the positioning of the bottles. A geared DC motor will be used for running the conveyor system. The ratings of the DC motor is 12V and 50 RPM speed with a high starting torque of 70 Kg-cm (at no load). Toggle switches will be  used to serve as an inputs to the PLC.

SOFTWARE DESCRIPTION:

There are different languages used to program the PLC which includes. 

• Functional block diagram (FBD)
• Structure text
• Instruction list
• Flow chart
• Ladder diagram

Out of these five languages, ladder diagram is the most widely used language and is simple as compared to other languages. Ladder diagram will be used for the programming of PLC.

Benefits of the Project

Five Major Benefits of Automatic Bottle Fillers
Below are some of the common benefits that come with adding an automatic filling machine when packaging a product.

1. Speed

Of course, as mentioned above, automation often becomes a necessity simply due to the amount of product that must be produced. Automatic bottle fillers can produce a greater number of filled product in a shorter amount of time than using manual labor to hand fill or even fill in a semi-automatic fashion. This is probably the most obvious benefit of the equipment, as well as the most often cited motivation for adding automatic machinery.

2. Consistency and Reliability

In addition to speed, automatic liquid fillers offer both consistency and reliability above and beyond what is typically achievable by doing a fill by hand. Whether by volume, fill level, weight or otherwise, the automatic machines are accurate based on the filling principle being put to use. The removal of uncertainty and inconsistency is also a large benefit for packagers who need to hit specific production goals.

3. Versatility

Automatic filling machines are manufactured to handle multiple container types and sizes, and can even run more than one product in many cases. Very few companies package one product in one container, but rather have a variety of products and/or containers that must be prepared for the end user. The versatility of automatic liquid fillers allows a packager to set up one machine to run many or all of the product and container combinations in use.

4. Easy Operation

Almost every automatic bottle filler will be centrally controlled by an easy to use, touch-screen operator interface. While the interface allows an operator to enter indexing times, fill durations and other settings, as well as turn on and off components of the machine, the Recipe Screen will likely be used more than any other. The Recipe Screen allows all of the settings for a bottle and product combination to be stored and recalled at the touch of a button! So as long as LPS has sample products and containers, automatic liquid fillers can often be primarily set up on the production floor by the touch of a button, about as easy as the operation of a filling machine can get.

5. Ability to Upgrade

A big benefit of automatic filling machinery is the ability of the equipment to grow with the company when manufactured properly. In most cases, simply planning for the addition of more heads in the future can allow a liquid filler to grow with the company as the demand for the products grow or additional liquids are added to the line. In other situations, components such as different nozzles, neck guides and more can be added or modified to accommodate changing product lines.

Technical Details of Final Deliverable

The final deliverable will contain a complete prototype system which can be deployed in a small scale industries. The final deliverable will includes a Siemens PLC SIMATICS S7 1200 is used for control purpose. Input supply to the PLC is given through a SMPS 24V DC 5Amps. A photoelectric sensor will be used for the positioning of the bottles. For conveyer belt  a geared DC motor (12V and 50 RPM speed) will be used. 

Final Deliverable of the Project HW/SW integrated systemCore Industry OthersOther Industries Manufacturing Core Technology RoboticsOther Technologies Others, Clean TechSustainable Development Goals Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	79317
PLC board (high speed)	Equipment	1	29277	29277
touch screen	Equipment	1	15940	15940
inverter	Equipment	1	6000	6000
servo system	Equipment	3	1500	4500
photo electric senser	Equipment	3	1200	3600
pneumatic components	Equipment	5	700	3500
solenoid valve	Equipment	5	1300	6500
Thesis print and binding	Miscellaneous	5	2000	10000