PLC based Automatic Bottle filling and capping
This work provides with a lot of benefits like low power consumption, low operational cost, less maintenance, 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 many industrial manufacture
2025-06-28 16:28:48 - Adil Khan
PLC based Automatic Bottle filling and capping
Project Area of Specialization Artificial IntelligenceProject Summary Literature ReviewThis work provides with a lot of benefits like low power consumption, low operational cost, less maintenance, 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 many industrial manufactures.
The word “Automation” itself emphasizes on making a typical process automatic which in turn will reduce the human work and thus will promote productivity. Industries will be productive only when they will adopt to the high-end technology available in the markets. So, by implementing the use of PLC’s in their processes, industries will take a step forward towards the era of new industrialization. PLC plays a very important role in the world of automation. It is the main part of the system which makes the whole process simple, flexible and accurate. A bottle filling system with
PLC allows the user to fill the bottle till a desired level without wastage of the liquid.
Industry automation becomes a spacious field in manufacturing which had important role in an extensive range of industries beyond manufacturing. Now-a-days the rapid development of manufacturing and technology has led to an increase in production level. Where the production managers are faced challenged to reduce the cost of the product with maintaining product quality within a time framework and due to the increased demand for on consumer products so competition among manufacturing companies has become dependent on cost, accuracy, time, and quality for that the key to such a problem is the use of integrated processes in the industry. Programmable logic controller (PLC) is extensively used in industrial automation and it act as a brain in industry application. PLCs in the industrial field are utilized to control a certain process in order to get better performance and higher accuracy to give more production in an efficient manner.
Project Objectives Aims & Objectives- Maximum integration
- Design (prototype)
- Implementation
We have divided SDP into three parts as given o Preparation of Model
o Implementation of Model / Finishing Hardware Work o Programming & Automation o Analysis and Result Formation o Final Write-up & Thesis Submission
Project Implementation Method Methodology of SDPThe hardware system contains on three main components; the moving part which is the conveyor move by DC motor, water filling and control equipment using PLC. The system therefore has conveyor belt, PLC, DC motor, electrical valve, sensor. Also, there are tank, plastic tube, relay.
A conveyor belt is used on which the bottles are placed. The position of the bottle is sensed through IR sensor. IR sensor gives output as logic ‘1’ or logic ‘0’ and depending upon its output corresponding motor turns ON. The filling operation is done with automatic detection of volume of bottle and selection the amount of liquid to fill the bottle. The filling process is done based on timing. Timer is used for defining the time according to that the preset value is set and depending on the preset value the pump is switched ON.
The input module includes IR sensors. There are three IR sensors one is used to detect the position of the bottle on the conveyor belt and two pairs of IR sensor are used to detecting the volume and also for detecting the position of the bottle for filling process. The input of conveyor belt where the bottles are fed the first IR sensor is placed. This sensor is used to detect the proper position on the conveyor. The other two pairs are kept at the filling operation to detect the proper position for filling operation and simultaneously for detecting the volume. These sensors also help to stop the conveyor. Hence inputs are given to input module.
DC motor and pump are the output devices used for the bottle filling process. These are connected to the output module. The DC motor is used to run the conveyor in forward direction. There is one pump used for the filling process. These are the output devices used in the bottle filling process.
Benefits of the ProjectTo bring the economic progress and increase the productivity. The system shall be Reliable, Flexible, Time saving. We shall gain more knowledge about various processes directly used in industries such as filling, capping etc. and learn about Programmable Logical Controller (PLC).
Our SDP has a vast application in bottle filling industries like mineral eater, Carbonated water filling, milk filling, medicine industries and paint filling etc. Our project will make outdated system more reliable, user friendly layout, low power consumption, maximum output and easy troubleshooting.
Technical Details of Final DeliverableWe have divided SDP into three parts as given o Preparation of Model
o Implementation of Model / Finishing Hardware Work o Programming & Automation o Analysis and Result Formation o Final Write-up & Thesis Submission.
| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 49400 | |||
| PLC | Equipment | 1 | 10000 | 10000 |
| CONVEYER SYSTEM BELT | Equipment | 2 | 4000 | 8000 |
| DC MOTORS | Equipment | 4 | 1500 | 6000 |
| WATER SOLENOID VALVE | Equipment | 2 | 500 | 1000 |
| SENSOR | Equipment | 3 | 800 | 2400 |
| RELAY | Equipment | 3 | 1000 | 3000 |
| CAP HOPPER | Equipment | 2 | 500 | 1000 |
| CAPING BODY | Equipment | 1 | 3000 | 3000 |
| FRAME | Equipment | 1 | 10000 | 10000 |
| OTHERS | Miscellaneous | 1 | 5000 | 5000 |