Design and Implementation of Automatic Filling and Mixing System
In small industries, filling and mixing of any product or a system is performed in manual mode, which consumes more time, human efforts, maintenance, and a certain person to monitor the process. In manual mode, precise and accurate monitoring and controlling of the parameters like temperature, volum
2025-06-28 16:31:42 - Adil Khan
Design and Implementation of Automatic Filling and Mixing System
Project Area of Specialization Electrical/Electronic EngineeringProject SummaryIn small industries, filling and mixing of any product or a system is performed in manual mode, which consumes more time, human efforts, maintenance, and a certain person to monitor the process. In manual mode, precise and accurate monitoring and controlling of the parameters like temperature, volume, flow rate etc. are very tough tasks. Any discrepancy in the filling and mixing process leads to a secondary quality product. It becomes necessary to shift the system from the manual method to automatic method.
Our project is to design an automatic mechanism of filling and mixing that will mix two different quantities in a single product with an accurate amount and produce high-speed production in less time based on PLC and the real-time controlling and monitoring using SCADA. In this project, we have chosen the Jelly product as an application for filling and mixing. This system can also use for other food products consists of these two operations.
In this project, we will develop a Human Machine Interface (HMI) as well as Graphical User Interface (GUI), which will provide the visualization of the system so that the user can easily monitor the mechanism and conveniently control it from the remote place. The procedure how different sensing inputs send the real-time acquired data to PLC, and how these PLCs can be interfaced with HMI is shown in Figure 1.
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Figure 1: Interfacing of input with PLC and HMI
- To design and implement an automatic mixing and filling system using PLC.
- To develop GUI and HMI for monitoring and control of mixing and filling system using SCADA.
There will be four containers, the first container contains liquid (water), the second container contains jelly powder with the respective pump and solenoid valve connected on it, and the middle container is mixing and filling container. Mixing container connected with a solenoid valve, drainage valve, level sensors to sense the water level in it and temperature sensor. The fourth container is cooling and contains the final jelly product.
Initially, the limit switch senses the mixing container then when the low-level sensor moves from NO contact to NC contact, the pump in the container of water will be activated and begin filling the mixing tank. The pump continues filling the container until the level reaches its maximum at a higher level. The load cell will use to find the accuracy of weightage of liquid and jelly powder.
When the high-level switch will be sent a signal to PLC, the water pump will shut down so that no more water enters the mixing container and then heating stove is activated and will start to boil the water till the temperature sensor is activated.
Then the motorized ball valve activates, and flow of powder starts continues till the delay of a few seconds after that DC Motor starts rotating for a few seconds. Then the valve of mixing container opens to pour the mixture for the cooling purpose. After again the valve, the pump of the water container and dc motor activates to wash the mixing container for few seconds of delay and then a drainage valve activates to drain out the water inside the container. After this, the process continues till the stop switch will not be pressed.
The operational flow chart is shown in figure 2:
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Figure 2: Operational flow chart
The connectivity of input and output parameters with PLC(S7-300) are shown in figure 3:
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Figure 3: Input and output parameters connectivity with PLC (S7-300).
Benefits of the ProjectIf Looks toward the manual procedure of filling and mixing, it takes more time, human efforts and a certain person to watch out the process for example, if we make a tea, it is difficult to take an exact litre of milk, maintain exact temperature and quantity of products. This system can resolve that type of problems and provides accuracy, better efficiency and high production in less time than a manual system.
And it is difficult to monitor the different parameters of the system manually so by using SCADA, we will easily visualize the system and control the different parameters from a remote place, it is not necessary to be there in the plant.
Technical Details of Final DeliverableWe will use Siemens S7-300 PLC, which acts as the heart of the system. The system sequence of operation is designed by ladder diagram. The final project will be the hardware prototype embedded with several electronic and electrical devices such as sensors, pumps, motors, valves, heater and the software (Semantic step-7 to program the PLC s7-300) and Win CC v7.5 for SCADA. It directly interacts with devices and more through human-machine interface (HMI) software using Ethernet.
- Water level sensor (220v dc float sensor) will use to detect the level of water.
- Beam type Load cell will be used for the Load measurement of liquid and powder quantity.
- AD620 (Op-amp) IC will amplify the signal from the load cell and water level sensor.
- Limit Switch will be used to detect the container in which the final amount or mixed amount is to be filled.
- The dc motor will be installed in mixing tank with pre-defined PWM value to set its speed, it will stir the heated powder and liquid in the mixing tank.
- The Solenoid Valve (Normally Closed Type) will use to control the flow of liquid
- The submersible pump will use to push the water from low level to high level.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 69700 | |||
| PLC Siemens | Equipment | 1 | 36700 | 36700 |
| Solenoid Valve | Equipment | 3 | 1200 | 3600 |
| AD620(Amplifier Circuit) | Miscellaneous | 2 | 300 | 600 |
| Heating Stove | Equipment | 2 | 1550 | 3100 |
| DC motor | Equipment | 1 | 4500 | 4500 |
| Beam type Load Cell | Equipment | 3 | 520 | 1560 |
| Motorized Ball Valve | Equipment | 2 | 7550 | 15100 |
| Connecting wires | Miscellaneous | 50 | 10 | 500 |
| Water level(Float Sensor) | Equipment | 2 | 1500 | 3000 |
| Temperature Sensor(Thermocouple) | Equipment | 2 | 520 | 1040 |