Smart Milk Packaging Machine
Pakistan is the 4th largest producer of milk in the world but unfortunately, we are continually seeing an old-fashioned packaging procedure for Milk in dairy farms and local marketplace. Packaging and quality testing is an essential part of the dairy industry. While manual milk packaging procedure i
2025-06-28 16:29:21 - Adil Khan
Smart Milk Packaging Machine
Project Area of Specialization Mechatronics EngineeringProject SummaryPakistan is the 4th largest producer of milk in the world but unfortunately, we are continually seeing an old-fashioned packaging procedure for Milk in dairy farms and local marketplace. Packaging and quality testing is an essential part of the dairy industry. While manual milk packaging procedure i.e., by-hand filling of milk in plastic bags using steel containers, really has some flaws that need to be taken care of, especially when it comes to its wide usage in variety of foodstuff in different forms and the health benifits accociated with it.
Various machines are available for this purpose, but the issue still exists because they are either too expensive to purchase or, only meant for continuous packaging. This is because of their complex mechanisms. This project is focusing on a Microcontroller based Smart Packaging machine offering a user-friendly Interface, enabling the user to fill specific volume of milk with accuracy which is then followed by a pneumatic cylinder-based sealing mechanism. The machine will be able to pack any number of pouches (Bulk or Single) of any volume entered from the interface.
Moreover, uncertainty about the quality of milk by consumers, which may cause serious health issues, requires frequent laboratory tests and visits in order to make sure that the milk is not adulterated and is free from contamination. Punjab food authority has initiated mobile testing labs which tests milk quality (percentage of Fat, SNF, Protein, Lactose, Salt, added water, PH, Density and Temperature of the sample) at the entrance points of the city to make sure that the milk is not adulterated. For this purpose, our project aims to install an Smart Milk Analyzer to this Packaging Machine.
The stated Automatic, Smart, and user-friendly machine is the need of our society. It is beneficial to local milk sellers in saving labor, ensuring hygiene, ensuring quality of milk, precise volume filling, and handling more customers.
Project ObjectivesThe major objectives of our project are to design:
01. A machine which is cost effective (Approx. 80000 PKR)
02. A machine which is easy to operate and has a user-friendly Interface comprising of an Input Keypad and LCD.
03. A machine which delivers accurately filled and sealed milk pouches without any leakage with an accuracy of +2%.
04. A Machine with pouch Filling and sealing time of 4-5 seconds ( for 1000ml) with an Internal storage tank capacity of 80-100 liters
05. A machine which analyzes the milk quality and displays the percentage of Fat, SNF, Lactose, Proteins and Density within 5 seconds..
06. To do data logging to collect important machine parameters and milk usage statistics, and to upload data to a cloud server
07. A machine which has a stainless-steel body and is easily cleanable so that the hygiene, appearance and durability of the machine is guaranteed.
08. A machine which has two options for filling.
i. Filling by number of liters.
ii. Filling by pre-defined rates/liter.
09. A machine which is capable of filling a Minimum of 250mL and a Maximum of 2000mL.
Project Implementation MethodMethodology we are adopting to accomplish this project is stated as under.
1. Making rough sketches of the machine and individual mechanisms.
2. Making 3D CAD models.
3. Finalizing the electronics components list, collecting the required components, and developing the final circuit.
4. Mechanism wise fabrication and Programming on Arduino (puller, precise filling and sealing mechanism).
5. Developing Milk analyzer circuitary.
5. Fabrication of main structure and storage tank.
6. Assembling all the mechanisms on the main structure.
7. Final testing.
To achieve the stated goals, we will use a stainless-steel body.For more than 65 years the stainless steel is in the dairy industry due to its high resistance to corrosion and chemicals. Stainless steel is durable and having a smooth surface which can easily be cleaned. It also prevents and bacterial contaminations.
In order to make it convenient for the user it has two options for filling and a range of up to two (2) liters of one-time filling. Keeping cost-effectiveness and instant result delivery in mind, we will be using an Ultrasonic sensor-based testing technique to analyze and produce instant test results. These results can also be communicated to larger laboratories and authorities in future.
A pneumatic cylinder-based punch sealer is selected for sealing the pouches as Pneumatic cylinders are fast acting and cheaper because air can be easily stored, obtained and is inexpensive. A Pneumatic system usually has long operating lives, needs negligible aftercare. Pneumatic systems are less subject to damage and shock. We will be using an accurate flow sensor and submersible pump (both 60 liters/min or above) for precise filling and a solenoid valve to instantly shut off the milk supply after the required volume is filled.
Benefits of the ProjectBENEFITS OF THE PROJECT:
Reduce Human efforts and labor Cost:-
Most businesses (specialy local market) are unable to afford the labour cost. Hiring more labour can cost a large sum of money and reduce the profit as well.
On the other hand a machine requires less labour and negligible maintainance cost.
Hygiene Assurance and Precise filling:-
Manual packaging causes improper hygiene, uneven fillling, and wastage of product. This machine will avoid the stated flaws by precise filling and sealing the milk pouches without human interaction.
Enhanced production rate:-
Based on our survey this machine is five times* faster than manual milk packaging (for 1000ml) pouch. It helps us deal with a large number of customers in less amount of time.
- Surveyed manual milk pouch filling time (1000ml) = 25 seconds on average.
Health:-
The built-in analyzer allows the customers to know about the qualtity of milk they are consuming. It assures that the milk is free from any kind of adulterants.
Authorities can also keep a check on the quality of milk being sold.
Cost Effective:-
Keeping the machine cost effective is beneficial for the milk sellers to purchase even in low budget.
Apart from these major benefits the machine is also valuabe in:
- The products look attractive
- Increases sales
- Customer satisfaction
- Low Wastage etc.
The technical details of the final machine are listed as under:
1. Technically the machine will be able to pack 700 pouches/hour (Taking reference of 1000ml).
2. The pouch will have a three sided seal (Top, Bottom and Back).
3. The plastic roller width for making a pouch is 13 inches (Taking reference of 1000ml).
4. The thickness of plastic pouch is 70 Micron (7 gauge).
5. Dimensions of the machine are 60cm × 60cm × 160cm (depth × width × height).
6. 304 grade stainless steel will be used for the machine body.
7. The internal storage tank capacity of the machine willbe 80L - 100L.
8.The control unit of the machine will have Start/Stop switches, Numeric keypad, 16x2 LCD and an emergency STOP switch.
Final Deliverable of the Project HW/SW integrated systemCore Industry FoodOther IndustriesCore Technology Internet of Things (IoT)Other TechnologiesSustainable Development Goals Good Health and Well-Being for People, Responsible Consumption and ProductionRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 77000 | |||
| Pneumatic Cylinder | Equipment | 1 | 5000 | 5000 |
| Arduino | Equipment | 2 | 1500 | 6000 |
| Pressure pump | Equipment | 1 | 4000 | 4000 |
| Submersible Pump | Equipment | 1 | 5000 | 5500 |
| Sensitive Flow Sensor | Equipment | 1 | 1000 | 1000 |
| Servo Motor for Puller | Equipment | 1 | 4000 | 4000 |
| Frame (Main body) | Equipment | 1 | 20000 | 20000 |
| water proof ultrasonic sensor | Equipment | 1 | 2000 | 8000 |
| Machining and Fabrication Cost | Equipment | 1 | 15000 | 7000 |
| Other components (resistors, capacitors, op-amps,transistors,PCB etc) | Equipment | 4 | 500 | 2000 |
| LCD screen (128x64) | Equipment | 2 | 1600 | 4500 |
| Miscellaneous (Industry travel, courier charges, labor, Photo paper) | Miscellaneous | 1 | 10000 | 10000 |