PROJECT ON BOTTLE

FILLING , CAPPING
AND PACKING
SYSTEM
INTRODUCTION:

 PLCs are used in many real world applications. In any

industry to achieve automation PLC is the first choice.
 Traditional Methods of bottle filling is time consuming and
expensive.
 Filling is a task that carried out by a machine which packages
liquid products such as cold drinks, water or milk etc.
 We control the entire system by programming the PLC
(Programmable logic controller).
KEYWORDS:
 PLC S7-1200
 Photo electric sensor
 Main Conveyer belt
 Box conveyer
 Liquid feeding valve
 Capping machine
 Rapping machine
 Bottle picking robo
DIAGRAM: start

feeding

capping

labelling

packing

Process repeat
 INPUT LIST:
SR. NO INPUT NO. INPUT NAME
1 I0.0 STOP
2 I0.1 START
3 I0.2 S1
4 I0.3 S2
5 I0.4 S3
6 I0.5 BOTTLE IN GOOD
CONDITION SENSOR
7 I0.6 BOX SENSOR
8 I0.7 BOTTLE IN BOX
DETECTOR
9 IW64 ANALOG INPUT IN FORM
OF LIQUID
10 I1.0 DEFECTED BOTTEL
SENSOR
OUTPUT LIST:

SR NO. OUTPUT NO. OUTPUT NAME

1 Q0.0 CYCLE START
2 Q0.1 MAIN CONVEYER
3 Q0.2 LIQUID FEEDER
4 Q0.3 CAPPING
5 Q0.4 RAPER
6 Q0.5 BOX CONVEYER
7 Q0.6 BOTTLE PICKING ROBO
8 Q1.0 BOTTLE REJECTED
LADDER LOGIC:
 Above network is about cycle start..
 In this network i0.0 is given as stop and i0.1 is given as
start input.
 For using the whole machine simultaneously latching
have been done in this network…
 Also the cycle is started is shown by output showing
LED addressed as q0.0
 Above network is for the main conveyer of bottleing
system reset operation..
 The main conveyer will be reset in below conditions.
1. When s1 is detected.
2. When s2 is detected.
3. When s3 is detected.
4. When box conveyer is started.
5. when the cycle stopped.
 Here the positive pulse of s1 contact is used for one time
detection.
 Above network is for the main conveyer of bottleing system set
operation..
 The main conveyer will be set in below conditions.
1. Whenever cycle started.
2. Whenever M memory M1 detected.
3. Whenever M memory M2 detected.
4. Whenever M memory M3 detected.
5. Whenever M memory M4 detected.
 Here the positive pulse of cycle start and M memory M1 is used
for only time detection.
 As shown in network 4, whenever s1 sensor detected
then the main conveyer stop and liquid feeder is start.
 This liquid feeder is actually solenoid valve.
 Whenever the required liquid is feed in the bottle then
the liquid feeder is stop to feed the liquid in bottle. And
then after the main conveyer start.
 The liquid feeing is done by analog input in our case as
shown in network 5.
 In our case the address of the analog input channel is
IW64
 Network 6 is used to convert the integer in to double
integer in given memory address.
 Network 7 is used for the scalling purpose so we see
that how much liquid is feed in the bottle.
 In this scalling method we use the multiplication and
division method.
 Whenever required liquid feed in the bottle then
automatically the main conveyer start and that time the
liquid feeder stop. That is shown in the network 8.
 Now whenever the sensor s2 detected then the main
conveyer stop and the capping process start. That is
shown in network 9.
 Whenever the capping process start , after 2 seconds the
capping process is stop automatically.
 When the capping process stop then after the main
conveyer belt start.
 Whenever the s3 sensor detected then after the main
conveyer belt stop and at that time the rapper process is
start.
 When the rapper process start , after 2 seconds this
process stop automatically. And that time the main
conveyer start.
 Now the bottle is in good condition. It have liquid, cap
and rapper.
 Whenever the bottle in good condition sensor is
detected then the box conveyer start and also the main
conveyer stop.
 When the box sensor is detected then the box conveyer
is stop. And that time the bottle picking robo start to
work. This robo pick the bottle from the main conveyer
and put in the box.
 If any bottle is defected then the defected bottle sensor
is activated and this bottle is rejected.
 When the robo put the bottle in the box then after this
robo is reset. And also the main conveyer is start.
 This process is continuous.
ADVANTAGES & CONCLUSION:

 A total control is made in a filling is achieved. The

present system will provides a great deal of applications
in the field of automation, especially in mass production
industries where there are large number of components
to be processed and handled in a short period of time
and there’s need for increased production.
 The programming to this system developed is flexible,
quickly and easily.
 This will increase the total production output; this
increase in production can yield significant financial
benefits and savings.
LIMITATION:

 It can only fill approximately one bottle at a time. The process

can be efficiently used in water filling system. These types of
fluids are handled mainly by the solenoid valve and nozzle
used. So the range of fluid types is not so wide.
 Positioning the solenoid valve is a critical issue and proper
care is needed.
 Another disadvantage is, no proper guidance for the bottles to
move. And making the system to cause imbalance vibration.
FUTURE SCOPE:

 By the installation of jet nozzle and strong solenoid valve

can reduce the time to fill bottles and can efficiently increase
productivity. A guide way could be used in case of vibration.
 The nozzle positioning must be given more care. The
system could be redesigned for increased bottle size and
productivity.
 Also we can use the round conveyer machine for filling more
bottles at a time as seen in next slide.
 y o u
T h a nk