BOTTLE FILLING PLANT FOR MULTIPRODUCT 1Mayank P. Solanki,

2Neeraj Saini,

3Amit N. Singh,

4Deepak Vyas

Student, Electronics & Communication department, Laxmi institute of Technology, Sarigam-

Valsad. Gujarat

Corresponding Author Detail:

Mayank P. Solanki

Student, ECE Department,

Laxmi institute of Technology,

Sarigam-Valsad, Gujarat.

Internal Guide Detail:

Mrs.Suchita Borkar Assistant Professor, ECE department,

Laxmi institute of Technology,

Sarigam-Valsad. Gujarat.

ABSTRACT

Filling is a task carried out by a machine that packages liquid products such as Soft drinks, Oils,

Water, Syrups, Chemicals or any other Pharma product etc. Traditional methods of bottle filling

involved placing bottles into a conveyor belt and filling only one product at a time. This method is

time consuming and expensive.

Our project aims at filling more than one product simultaneously at a time on a single Conveyor belt.

The filling operation takes place in a synchronized manner. It also includes a user-defined volume

selection menu through which the user can input the desired volume to be filled in the bottles. The

entire system is more flexible and time saving. The filling operation is controlled using

Programmable Logic Controllers (PLC’S). This is because PLC’s are very flexible, cost effective,

space efficient and reduces complexity. By programming the PLC we control the entire system.

SCADA (Supervisory Control and Data Acquisition) is used to monitor the process.

KEYWORDS: PLC, SCADA, Sensors, Automation.

INTRODUCTION

The field of automation has a notable impact in a wide range of industries beyond manufacturing. It

is the use of control systems and information technologies to reduce the need for human work.

Automation plays an increasingly important role in the world economy vices. One of the important

applications of automation is in the soft drink industries, where a particular liquid has to be filled

continuously. The trend is moving away from the individual device or machine toward continuous

automation solutions. Totally Integrated Automation covers the complete production line, from

receipt of goods, the production process, filling, to shipment of goods. The various processes are

controlled using a PLC and is monitored using SCADA.

Our project is also an application of Automation wherein we have developed a bottle filling plant in

which two different products can be filled out on a single conveyor belt. The various processes are

controlled by PLC (Programmable Logic Controller) and monitored using SCADA.

OBJECTIVE

To develop an automatic bottle filling system with a deduction mechanism using sensors. Automatic

filling process for all the bottles simultaneously with a user defined selection for volume to be filled.

The containers will be stack on conveyor belt and will be filled with required quantity. As per

requirement product in the tank can be change as a result from both nozzle the same product can be

filled.

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METHODOLOGY

Containers are kept in position over a conveyor belt. They are sensed to detect their presence. IR

sensors are used for sensing the bottles. Depending on the output of IR sensor Pneumatic Valve will

slide the containers. Level sensor is used for sensing the level of liquid in container. Depending on

the output of the sensor the corresponding Solenoidal valve on and filling operation takes place. If the

particular bottle is not present then the Solenoidal valve in that position is switched off, thereby

avoiding wastage of the liquid. The filling operation is accompanied with a user-defined volume

selection menu which enables the user to choose the volume of liquid to be filled. The filling process

is done based on timing. Depending on the preset value of the timer the Solenoidal valve is switched

on for that particular period of time and the filling is done.

PROCESS DESCRIPTION

This chapter gives a detailed explanation of the various processes taking place in a complete bottling

system. The bottles are placed in parallel for filling two different products at a time as shown in fig.

When no bottles are kept in the input the system is reset. Depending on the numbers of bottles fed

into the input side the corresponding bottles are filled. The process also provided with user defined

volume selection menu.

BLOCK DIAGRAM

The block diagram (as shown in fig.1) of the process and its explanation is given below.

Figure-1 Block diagram

INPUT MODULE

The input module consist of IR sensors and level Sensors. There are three pairs of IR sensor whose

output is given as an input to the PLC. One IR sensor is use to detect bottle at the input side and two

more is used to sense the bottles for filling operation.

There are two level sensors used. One is used to detect level of liquid in tank1 and another one is

used in tank2.

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PLC

PLC is a solid state device. They are well adapted to a range of automation tasks. All control

operation is done using PLC.

24V is provided to the PLC through SMPS for their operation. The entire bottling process is done by

feeding the necessary condition into the PLC using ladder logic. Ladder logic is the method of

programming a PLC.

PLC consists of I/O unit, central processing unit and memory unit. The I/O units of the PLC act as an

interface to the real world. Input from the real world is given to the input unit which is manipulated

based on the programming and the results are given back to the real world through the output unit of

the PLC.

OUTPUT RELAY DRIVE UNIT

The operating voltage of the output devices is low when compared to that of the PLC. The output of

the PLC is 24V whereas output device such as motor require only 12V for their operation. Hence the

output signals from the PLC are given through a relay drive unit which drives the output devices by

supplying the optimum voltage required for their operation. The 12V required for their operation is

available at the common terminal of the relay unit.

SCADA

Supervisory Control and Data Acquisition (SCADA) is a system for remote monitoring and control

that operates with coded signals over communication channels (using typically one communication

channel per remote station).

OUTPUT MODULE

The various output devices used in the bottling process are DC motor, Pneumatic Valve, Solenoidal

Valve and LED’s. These are connected to output module. The DC motor is used to run conveyor in

forward direction. Pneumatic Valve is used to slide bottle form one side to another. Two Solenoidal

valves are connected to the tank1 and tank2 for filling containers. LED’s are used for indication

purpose. These are the various output devices used in the bottling process.

The basic process (as shown in Fig. 1) involved in the bottling is explained as follows.

Figure-2 Process description

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BOTTLES DETECTION USING SENSORS

Bottles are kept in position on the conveyor belt at the input side. One IR Sensor is used at the

starting point to detect containers. Depending on the output of the sensor Pneumatic Valve will slide

the bottles from one side to another. Two IR sensors are used to detect the presence of bottles under

Solenoidal Valve. Depending on the output of the sensors the filling operation takes place. A time

delay is given in order to the status of the bottles. If the bottle is present the corresponding status bit

in PLC is set 1 else it is set to 0. The output of these sensors is given to the PLC and depending on

this output the filling process for the bottles takes place. Thus if all the n bottles are present in the

input side then the sensor gives the corresponding output to the PLC which in turns switches ON the

corresponding tanks for filling operation take place. If a particular bottle is not present the

corresponding tanks remain OFF.

FILLING OPERATION

Once the Start button is pushed the motor switches ON and starts rotating the Conveyor belt in the

forward direction. At the starting point IR sensor will detect the bottle ant Pneumatic valve Switches

ON and Slide the Bottles according to even or odd. The bottles then reaches to the desired places for

filling purpose and motor switches OFF and both the Solenoidal Valve start filling the bottles. There

are two tanks present in the filling side namely: product 1 and product 2 have two level sensors

respectively.

USER-DEFINED VOLUME

The filling operation is accompanied with a user defined volume selection menu. The desired volume

fed into the PLC and depending on the volume the filling of liquid takes place. The filling is done

using timing operations. Thus the tank remains on for the preset value of the timer and switches off

once time is out. Once the filling process is done the conveyor starts moving again.

FUTURE SCOPE

1. In future we will add star wheel construction to transfer containers.

2. We will add capping machine employing a rotary construction for the capping of containers.

3. We will also make it portable so that it can be used at small places.

CONCLUSION

The main objective of this paper was to develop and increased bottle filling based on certain

specifications. This was successfully implemented.

A lot of additional features like filling of multiproduct on a single Conveyor belt, user defined

volume selection etc. were added in different stages in our work and the desired results were

obtained. PLC is used to control the various operations and monitoring is done using SCADA.

REFERENCES

1. Paul La Barre Sainte, “in line bottling plant”, United States Patent, application no. 08/9133,929

issued on Dec. 7,1999

2. Bernhard Herbert, “Container filling plant, such as a beverage bottling plant, for filling containers

with a liquid beverage and for closing filled containers”, United States Patent, application no.

13/208,409 issued on August 12, 2011.

3. Molitor Bernd, “Method of cleaning returned beverage bottles in a bottle filling plant, a method

of introducing treatment fluid into containers to remove contaminants there from in a container

International Journal of Scientific Research in Engineering (IJSRE) Vol. 1 (3), March, 2017

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filling plant, and an arrangement therefor”, United States Patent, application no. 12/437,956

issued on May 8, 2009.

4. Till, Volker, “Beverage bottling plant for filling bottles with a liquid beverage filling material,

having a transfer device for the transfer of containers from a transfer star wheel to the carousel of

a container handling machine”, United States Patent, application no. 10/954,012 issued on

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