Production line of water bottles

Submitted by: Mai Amr Hassan

Submitted to: Eng Yasmin Morgan

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Table of Contents
Table of table..............................................................................................................................................III
Table of figure.............................................................................................................................................IV
Abstract.......................................................................................................................................................V
introduction.................................................................................................................................................6
The stages of production line......................................................................................................................7
function.......................................................................................................................................................8
Circuit Design.............................................................................................................................................10
The circuit working....................................................................................................................................11
Run the circuit...........................................................................................................................................13
Steps to make a PCB circuit on Proteus.....................................................................................................16
Programming.............................................................................................................................................21
Components..............................................................................................................................................25
Draw the production line in the SolidWorks..............................................................................................26
Draw the box in the solidwork...................................................................................................................27
Assembly box in the production line.........................................................................................................28
limitations..................................................................................................................................................29
Problems and their solutions.....................................................................................................................30
Advantages................................................................................................................................................32
Disadvantages............................................................................................................................................34
Time plan................................................................................................................................................37
Critical path...............................................................................................................................................38
Feasibility study.........................................................................................................................................39
Time plan of the circuit..............................................................................................................................45
Components & Function............................................................................................................................47
Technical feasibility study..........................................................................................................................49
Health and Safety issues............................................................................................................................53
Environmental and Sustainability issues....................................................................................................55
Recommendation and improvement.........................................................................................................57
Conclusion.................................................................................................................................................60
References.................................................................................................................................................61

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Table of table
Table 1:Quantity and price of component.................................................................................................24
Table 2:Time of project..............................................................................................................................42
Table 3:Time of the project (circuit)...........................................................................................................43
Table 4:Machines and tools of the production line....................................................................................48
Table 5:Software programs........................................................................................................................50

Table of figure
Figure 1: Circuit of design..........................................................................................................................10

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Figure 2:The conveyor belt is running........................................................................................................13
Figure 3:The filling stage is running...........................................................................................................14
Figure 4:The capping stage is running.......................................................................................................15
Figure 5:Circuit design on proteus.............................................................................................................16
Figure 6:Circuit in PCB layout.....................................................................................................................17
Figure 7:the back view with component....................................................................................................18
Figure 8: the back view with component ..................................................................................................19
Figure 9: Circuit layout with components..................................................................................................20
Figure 10:Circuit layout without the components....................................................................................20
Figure 11:programming.............................................................................................................................21
Figure 12:programming.............................................................................................................................22
Figure 13:programming.............................................................................................................................23
Figure 14:programming.............................................................................................................................24
Figure 15:Production line design in the solidwork.....................................................................................26
Figure 16:Box design in the solidwork.......................................................................................................27
Figure 17:Box in the production line..........................................................................................................28
Figure 18:Time plan in the gnat project program......................................................................................37
Figure 19: Time plan in the Gant project program.....................................................................................37
Figure 20:Critical path................................................................................................................................38
Figure 21: Time plan in the Gant project program (feasibility study).........................................................45
Figure 22: Time plan in the Gant project program (feasibility study).........................................................45
Figure 23: Rotary in solid work Figure 24: The table in solid......................................................58
Figure 25: Conveyor belt in the solidwork.................................................................................................59
Figure 26:The production line in the solidwork after improve...................................................................59

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 Abstract
A circuit production line for filling and capping
water bottles so that a number of bottles are
produced at the same time.

5
 introduction
A circuit production line that includes a filling stage
and a water bottle capping stage in an efficient and
automated manner. This is to maintain the quality
of the product.

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 The stages of production line
These stages represent: -
1 - Filling stage: The water filling process is carried
out using automatic machines that fill the bottles
with the appropriate amount of water.
2 - Covering stage: This stage refers to covering the
opening of the bottle with a tight cap to prevent
leakage.
☆☆ Choose the appropriate cap with the type of
bottle.
☆☆ After placing the cap on the bottle opening,
the cap must be pushed or twisted to secure it
tightly to the bottle.
☆☆ To ensure that the bottle does not leak water
and the cap is installed correctly, this is when
tilting the bottle to ensure that there is no leakage,
or gently pressing the cap.

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 function
● The project aims to produce and bottle water in
safe and healthy bottles, and cover the bottles
with tight covers to maintain the quality of the
water and ensure that there are no leaks from the
bottles.
● My goal in the project is also to produce a
number of bottles at the same time, in order to
save time and effort.
☆☆ This is done by (instead of only one stage of
each stage, the number of each stage will be the
same as the number of bottles that enter the
production line and the number of bottles that I
want to take out at the same time).
》》For example: If I want to remove 4 bottles
from the production line, the number of filling
stages must be (4), and the number of capping
stages must be (4).
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 Circuit Design
Figure 1: Circuit of design

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 The circuit working
There is a control unit and this control consists of 3
switches.
● Switch 1 starts the process that is taking place
and starts the entire production line.
》Without pressing this switch, no stage will start.
Switch 2 I want to do stop, to close the system
completely.
》There is a Switch Reset, it will completely close
the processes, and in order to start the system
again, I have to go back and do start again.
● Switch 3 is an emergency, by pressing it
everything stops, and when I return it to the
original one, it will complete the process as it is.
The running belt is a DC motor, and a transistor is
used to operate the motor.

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● The filling stage is a sensor. As soon as the sensor
senses the bottle, the belt will stop, but the belt
will stop, but the anise can still sense the bottle.
》 After that, the filling stage will start working
because the valve will operate for a certain period,
and after this period the valve will close and the
belt will work again. Again, so that the bottle
moves to the next stage.
● The capping stage consists of 2 motors.
The motor moves linearly (it moves the shield
down to put the bottle cap on).
After that, the motor stops, and then the second
motor that starts to wrap the cap well on the
bottle. After that, the first motor starts again to
raise the shield up.

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 Run the circuit
Figure 2:The conveyor belt is running

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Figure 3:The filling stage is running

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Figure 4:The capping stage is running

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 Steps to make a PCB circuit on
Proteus
Draw the circuit design on proteus
Figure 5:Circuit design on proteus

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Circuit in PCB layout
Figure 6:Circuit in PCB layout

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Draw the 3D visualizer
Figure 7:the back view with component

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Figure 8: the back view with component

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Figure 9: Circuit layout with components

Figure 10:Circuit layout without the components

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 Programming
I use Programming Microcontroller
Figure 11:programming

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Figure 12:programming

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Figure 13:programming

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Figure 14:programming

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 Components
Table 1:Quantity and price of component

Components Quantity Price

Resistor 9 1 L.E
Capacitor 2 2 L.E
Switch 5 10
Crystal 1 5 L.E
Microcontroller 1 185 L.E
Transistor 3 15 L.E
Diode 1 2 L.E
Motor 3 50 L.E
Total Price 270 L.E

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 Draw the production line in the
SolidWorks
Figure 15:Production line design in the solidwork

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 Draw the box in the solidwork
Figure 16:Box design in the solidwork

This box protects the electrical circuit from

pollution and weather changes and preserves the
components and anything that will affect them.
Material of box 》steel

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 Assembly box in the production
line

Figure 17:Box in the production line

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limitations
● I cannot perform two operations together.
● Once I start and the bottle has entered the
capping phase for a long time, the phase will not
start. I have to do the first filling process and then
cap.
The two processes must give each other peace
Meaning, when the filling is finished, you tell the
microcontroller that it is finished and let the filling
process be used by disable and the covering
process be used by inable, so the covering process
works and the filling process does not work.
When the coverage stage ends, the opposite
happens.
(Meaning, one stage must finish and then the
second one should start. This means that if one
stage is running and the second stage senses any
bottle, then it will not start unless a signal is
received from the microcontroller.)
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 Problems and their solutions
1- Programming
The Proteus program did not want to start the
programming and crashed a lot, because the pin
saved its signal.
The Senor felt as long as the bottle was in front of
him. So, when I pressed switch for a while, the
signal preferred (high) even if I removed my hand.
The solution: In programming, I knew each pin
separately.
2- I wanted to do a weight class
I did not know how to use a scale in Proteus, and in
simulation the topic is difficult and requires a lot of
time.
Because of this, I canceled the idea of making a
quality control stage to see if the bottle of water in
it reached the level it needed or not.

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3- I am not trained in programming the
microcontroller, so the programming was very
difficult and I did not know how to do the codes
correctly.
The solution: - I reviewed the codes and
programming of the microcontroller in general.
4- The circuit shape was very complicated in the
pcb, so it took me a lot of time until the circuit was
configured in the pcb.

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 Advantages
1 - There is a continuing demand for bottled water
due to increased awareness of the importance of
drinking pure and healthy water. Therefore, the
demand for bottled water remains strong in local
and global markets.
2- Consumer health and safety:
The water is bottled in safe and hygienic bottles,
providing consumer confidence in the quality of
the product.
Glass is a better option than plastic in some cases,
as harmful chemicals do not transfer from the
bottle to the water.
3 - Marketing and commercial differentiation:
Bottled water can be marketed in different and
attractive ways, giving the brand an opportunity to
stand out and be marketed based on the quality of
the product and the attractive design of the
bottles.
4- High profitability:
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The water bottling sector is considered one of the
highly profitable sectors, due to the continuous
and increasing demand for the product.
5- Expandable:
Additional production lines can be added or
production capacity increased to meet the
increasing demand.
6- Contributing to preserving the environment:
Using recyclable bottles.

☆☆ One of the most important features of this

project is the production of a number of bottles at
the same time.

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 Disadvantages
》》 Despite the advantages mentioned before,
the production line project faces some
disadvantages and challenges, and among these
disadvantages are:
1 - Setting up the production line may require a
high initial investment.
The necessary equipment and machinery must be
purchased, in addition to hiring workers and
providing the necessary space for production.
Therefore it may be at a cost to some investors.
2- Intense competition:
There is strong competition in the water bottle
filling and capping industry. There are many
competing brands and companies.

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3- Distribution and Marketing:
Distributing and marketing the product can be a
challenge, especially at the beginning of the
project.
Relationships must be built with distributors and
dealers to reach target markets.
Marketing also requires a high effort to educate
consumers about the benefits of water and push
them to buy the product.
☆☆ One of the most important disadvantages is
the use of a microcontroller in programming the
production line.
● Because the microcontroller is not used in
industrial things such as the production line.
This is for many reasons, including:
●● The microcontroller cannot withstand the
temperatures found in factories.

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●● The microcontroller performs sequential
processes, which means that a process must be
terminated in order to start a new process.
●● The microcontroller does not run some
operations (in parallel) like the PLC.
》》Because the PLC can run two processes at the
same time.
》》But in the microcontroller, in order to
operate the capping stage, the bottles must have
passed the filling stage.
》》It is not possible for me to cover the bottles
in bottles during the filling stage. The bottles must
complete all stages and then other bottles enter
the production line.

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 Time plan
Figure 18:Time plan in the gnat project program

Figure 19: Time plan in the Gant project program

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 Critical path
Figure 20:Critical path

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 Feasibility study
Operational feasibility study
● Description of production line
Water bottle production line for filling and
capping the bottle in an efficient and
automatic way.
Where there is a filling stage and a capping
stage in the production line.
1- Filling stage: Filling is done using an
automatic machine that fills the bottles
with the appropriate amount of water.
2- Capping stage: You place the cap on the
bottle well.

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● Description of circuit

》》The belt operates via a DC motor, and

the transistor is the one that operates the
motor.
》》As soon as the traffic stops, the filling
phase starts and the bottle is filled, and
this is done through a valve.
》》 Once the valve closes and the belt
starts, the bottle moves to the capping
stage.
》》The capping stage will work, and this
stage consists of 2 motors.

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● The motor moves linearly (to move the
moving part, it will go down and place the
cover).
● After that, this motor stops, and the
second motor is the one that will start, so
that this motor turns the cover well.
● After that, this motor will stop, and the
first motor will work to raise the moving
part up.

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● Function or purpose of production line

● Function or purpose of circuit

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● Time of the project (production line)
Table 2:Time of project

Tasks Weeks
Choose idea 2
Initial design 4
Specifications 1
Production plan 2

Problems and solving 1

Final design 3
Buying components 2

Manufacturing 5
Assembly 3
Test 1

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 Technical report 1

Presentation 1

● Time of the project ( circuit )

Table 3:Time of the project (circuit)

Tasks Days
Search for 3 ideas 4
Present the ideas 4
Approved of the idea 2
Search for design 5
Draw the design on 13
proteus
Buy the materials and 4
components
Modified simulation 4
Design layout 8
Print layout 1
Manufacturer of the 10
circuit

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 Circuit test 3
Technical report 5
Presentation 2

Time plan of the circuit

Figure 21: Time plan in the Gant project program (feasibility study)

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Figure 22: Time plan in the Gant project program (feasibility study)

● Components of the circuit

Components Quantity Price
Resistor 9 1 L.E
Capacitor 2 2 L.E

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Switch 5 10
Crystal 1 5 L.E
Microcontroller 1 185 L.E
Transistor 3 15 L.E
Diode 1 2 L.E
Motor 3 50 L.E
Total Price 270 L.E

Components & Function

1.Resistor

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limits or regulates the flow of electrical current in
an electronic circuit. Resistors can also be used to
provide a specific voltage for an active device such
as a transistor.
2.Capacitor
A capacitor is a circuit component that temporarily
stores electrical energy through distributing
charged particles on (generally two) plates to
create a potential difference.
3.Switch
A switch responds to an external force to
mechanically change an electric signal. Switches
are used to turn electric circuits ON and OFF and to
switch electric circuits.

4.Crystal

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A crystal oscillator is a digital timing device that
creates an extremely precise frequency-based
electrical signal by leveraging the mechanical
resonance of a piezoelectric element vibrating
crystal.
5.Microcontroller
A microcontroller is embedded inside of a system
to control a singular function in a device.
6.Transistor
transistor is to amplify the electric current in a
circuit. In its function as an amplifier, the
transistors are fed a low input electric current,
amplifying it, and thus it also produces a higher
output electric current.
7.Diode
diode is to allow an electric current to pass in one
direction (called the diode's forward direction),
while blocking it in the opposite direction (the
reverse direction).

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 Technical feasibility study
● Machines and tools of the production
line
Table 4:Machines and tools of the production line

Machines Function
Laser machine To cut the big large
parts of the project
professionally and
with high quality.

Bending machine There are some parts

of the project that will
be bent so we
will use the bending
machine.
Drilling machine To make holes in the
required parts.
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Cutting machine There are some parts
need to cut with hand
so we will use
cutting machine.
Welding machine To weld some parts
together to be one
part.
Screwdriver To install the screws in
parts.
Marker pen To determine and mark
the sizes on the sheet
metal for
cutting.
Meter To measure the length
and width of the sheet
metal.

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● Software programs
Table 5:Software programs

Software programs Function

Solid works to draw each part in

the project and make
assembly drawing to
make mechanical
simulation.
Microsoft word To write the reports,
making the flowchart
and logbook and other
papers.
Microsoft power point To make the
presentation of the
project.
Microsoft gant project To make the time plan
of the project.
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● Materials of the production line
☆ Aluminium ( Because it is very solid and
lightweight ).

● Materials of the ( box ) to protect the circuit

☆ Steel

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 Health and Safety issues
For a water bottle filling and capping production
line project, there are some health and safety
issues that must be considered. Here are some
important points:

1. General safety in the factory: Comprehensive

safety procedures must be established for the
entire factory, including providing appropriate fire
suppression methods, installing smoke detection
alarms and emergency evacuation devices, and
providing training for workers on safety
procedures.
2. Personal safety: Workers must be provided with
appropriate personal protective equipment, such
as gloves, goggles, protective masks, and
appropriate clothing, and raise awareness of the
importance of using them and following personal
safety procedures.

53
3. Dealing with chemicals: There are chemicals
used in the filling and covering process, such as
disinfectants and adhesives. The necessary
measures must be provided for the safe handling
of these materials, including storing them properly,
providing appropriate ventilation, and educating
workers about their dangers and safe handling
methods.
4. General cleanliness: Care must be taken to
maintain general cleanliness in the factory,
equipment and tools used in the filling and
covering process. The area should be cleaned
regularly and appropriate hygiene and disinfection
procedures applied to prevent contamination of
products.
5. Training and awareness: Appropriate training
must be provided to workers on occupational
safety and health, including training on using
equipment correctly and identifying potential
hazards and how to deal with them.

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 Environmental and
Sustainability issues
For a water bottle filling and capping production
line project, there are some environmental issues
that must be considered and measures taken to
reduce the negative environmental impact. Here
are some important points:

1. Waste management: An effective system must

be provided to manage waste resulting from
the packaging and covering process, such as
plastic, paper, and metal waste.

2. Sustainability in resource consumption: Strive

to reduce the consumption of natural resources,
such as water and energy. Effective technologies
can be used to improve water efficiency, use
renewable energy sources, and improve energy
efficiency in the manufacturing process.

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 3. Sustainable Packaging: Consider using
sustainable and recyclable packaging materials and
disposing of them in environmentally friendly
ways. You can use biodegradable materials and
reduce the use of non-biodegradable plastics.

4. Air and water pollution: Necessary precautions

must be taken to reduce air and water pollution
resulting from the manufacturing process, such as
using air and water purification techniques and
monitoring harmful emissions.

5. Preserving natural resources: One should

strive to preserve the natural resources used in the
manufacturing process, such as groundwater and
other natural resources. Actions can be taken to
conserve these resources and rely on sustainable
practices in their use.

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 Recommendation and
improvement
If someone else will implement this project.
I would like to advise him on these points:
1- The microcontroller is not used, because it runs
sequential processes, meaning a process must be
finished in order to start a new process, so this is a
waste of time.
But I recommend using a PLC, because it operates
in parallel, and because more than one process can
be run at the same time.
Also, the PLC has many features, including (when
any problem occurs, it is easy for the device to
show this problem), and this reduces the time in
which I search for what the problem is.

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2- Changing the shape of the design
So that the size of the production line is smaller.
This is done by adding improve Instead of having a
large distance between each stage and the next,
we will add a (rotating part)
As it has 3 stages, this reduces the follow-up
distances and the size of the production line, and
this also reduces the time in which the number of
bottles comes out Because the rotary part will
contain a number of bottles.

Figure 23: Rotary in solid work Figure 24: The table in solid

58
Figure 25: Conveyor belt in the solidwork

3- You will improve another

It is adding another stage, which is (Labeling).
To stick the label on the bottle.
This gives an attractive appearance to the product,
which will also attract the buyer.

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Figure 26:The production line in the solidwork after improve

Conclusion
The water bottle filling and capping production line
project is a very good investment opportunity, and
with the increasing demand for bottled water and
the growing awareness of water health, this
project can be profitable and sustainable.

60
 References
1. https://filltech-machinery.com/pro/
12000bph-water-bottling-machine/?
gad_source=1&gclid=Cj0KCQiA1rSsBh
DHARIsANB4EJbCy-
Tpu6Lw8lsCY_5NqDvIaNoiduxeV9Yva
k8j7AslhInZ3hHlxtMaAtiIEALw_wcB

2. https://www.king-machine.com/
products-category/water-filling-
machine.html?
gclid=Cj0KCQiA1rSsBhDHARIsANB4EJ
bRqr3MOH1tHsrzBmmj66eZzBnV3Wj
3B2hNKNQcycN8orRwZs-
CjJAaApH9EALw_wcB

61
3. https://www.linkedin.com/pulse/
what-bottled-water-production-
process-flow-chart-john-l-

4. https://www.sidel.com/en/water-ca-
1

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