Automated Bottle Filling and Capping

About The Company

In todays fast moving, evolving world with new technologies, Filmatic meets the
challenge with a new technology and a greater operational reality. Filmatic is a company founded
on July 2015. The name of our company comes from the phrase automatic filling since our main
specialization is filling system.

The circle-like logo of our company means cycle that can be interpreted as process. The
two quarter circle means step-by-step that can represent the stations involving the project. We
also choose it to be circle because that is how our processes will move, in rotary motion.
Our company provides service in the modern industries, laboratories and manufacturing
plants. Our goal is to provide simpler yet efficient way of automated process especially in filling
products.
Food markets, medicine companies, water refilling stations and many more industries
offer opportunities that can be a success by companies that have services like Filmatic.
Our company focuses on providing services like making a simpler automatic filling system for
industries especially for small businesses that are aiming for a quality production yet not so
expensive process mechanism.

Project Title:

Automated Bottle Filling and Capping

Starting Date:

July 20, 2015

Completion Date:

October 30, 2015

Proponents:

Project Manager: Mark Lorenz L. Lawas

Secretary: Jill B. Montero
Technical/Engineering Manager: Jose Mari O. Sanga
Sales Representative: Jenesa J. Villahermosa
Logistics Officer: Jenner Joseph A. Micaller
Administrative Officer: Christian G. Dorotan

Contents
About The Company......................................................................................................... 1
Executive Summary.......................................................................................................... 4
Section 1. Background...................................................................................................... 5
1.1

Project Purpose................................................................................................... 5

1.2

Machine Operation /Procedure................................................................................7

1.3

Safety Precautions............................................................................................... 7

1.4

System Process................................................................................................... 8

Section 2. Rationale.......................................................................................................... 9
2.1 Abstract................................................................................................................. 9
2.2 Project Justification................................................................................................ 10
Section 3. Project Framework............................................................................................ 10
3.1. Problems / Project Issues and How These Were Resolved.................................................10
3.1.1 Planning and Methodology..................................................................................... 10
3.1.2 Project Assembly................................................................................................. 11
3.1.2.1 Rotating Table............................................................................................... 11
3.1.2.2 Stations....................................................................................................... 13
3.1.2.3 Slider.......................................................................................................... 14
3.1.2.4 Panel.......................................................................................................... 15
3.1.3 Designing.......................................................................................................... 16
3.1.3.1 PLC Symbolic Addressing................................................................................16
3.1.4 PLC Ladder Diagram............................................................................................ 17
3.1.4.1 Main........................................................................................................... 17
3.1.4.2 Motor.......................................................................................................... 18
3.1.4.3 Filling......................................................................................................... 19
3.1.4.4 Capping....................................................................................................... 20
Section 4. Materials & Equipment...................................................................................... 21
4.1 Essential Materials for the Project..............................................................................21
4.2 Tools & Equipment Used......................................................................................... 29
Section 5. Project Outcome............................................................................................... 33
Section 6. Project Conclusion............................................................................................ 34

Executive Summary
Control engineering has evolved overtime. In the past, humans were the main method
for controlling a system. More recently, electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relay to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable
Logic Controller (PLC).
Control system is an integral part of modern society. It consists of subsystems and
processes assembled for the purpose of controlling the outputs of the processes. There are many
numerous applications that use control system around us. A control system provides an easier
and faster way of making a process` The reason that control system was built is for
power amplification, remote control and many more.
Our first project is an application of automation wherein we developed a bottle filling and
capping system programmed by PLC. The only difference of this project compared to the
common bottle filling process is that it was built to move in a circle or rotary motion. We come
up with this concept because we were thinking of making an automatic process that is new and
can be smaller than using with a conveyor since our first project is only a prototype, or just a
model of how our service may look like.
This bottle filling does not only mean filling liquid, you can also include small solid
objects like candies, capsules, tablets, etc. In our project, we prefer to use small solid objects so
that will not be that dangerous in our wirings and it cannot be that hassle if ever there might be
problem with the filling because if we use liquid, that may be a bit messy and has a tendency to
soak our model.

Section 1. Background
1.1 Project Purpose
This projects purpose is to make a smaller version of automated filling and
capping machine using programmable logic controller. Its target consumers are schools that
also study process automation who wants to have a sample model of the said subject.
Its purpose is also to apply all that we have learned in our course, to enhance and develop
our strategy in making process simpler yet effective one and to make a process that limits the
use of conveyor since it consumes too much space.

Specifications
The dimension of the base of the machine is 45 cm x 45 cm x 23 cm (length x width x height)
and the dimension of the whole product including input, fill station, cap station and output is 64
cm x 70 cm x 84 cm.

Bottles

Type: Non-Shielded
Height: 2-3 inches

Gears
Diameter: 4 inches

Diameter: 2.5 inches

Pneumatic Cylinder

Silo

Type: Double Acting

Diameter: 2.5 inches

Supply: 0 10 bars

Height: 11 inches

Stroke: 100mm, 150mm

5/2 Way Valve
Type: Monostable, Solenoid
Actuated
Proximity Sensor
Sensing Range: 0mm to 12mm
Supply: 10VDC to 30VDC

Dc Motor
Torque: 8-200rpm
Supply: 6-24VDC
Bolts and Nuts
Length: 4cm
Diameter: 10mm
Pushbuttons

Type: SPST
Lamp (Alarm)
Supply: 24 VDC

Type: Polyurethane
Limit Switch
Supply: 250 VAC,

Pneumatic Hose

1.2 Machine Operation /Procedure

a) The machine will be needing a 24 VDC supply for the sensors and solenoids to operate;
and a 220 VAC supply for the PLC.
b) Be sure to associate the panel first to the PLC by connecting wires from the labeled
terminals of the panel to the input and output terminals of the PLC.
c) After connecting the wires to the terminals, be sure to set the controller to its RUN
mode.
d) A green START pushbutton (green push button) is to be pressed for the machine to run.
e) When the machine starts running, the operator places the sample cubes on the first
conveyor. Cubes are placed manually and operators are needed since there are no
previous machines linked with the initial conveyor.
f) Package boxes are to be placed on the last conveyor manually where good products are
loaded.
g) A red STOP pushbutton is positioned near the start button. By pressing this button, the
machines operation can be stopped at any given time.

1.3 Safety Precautions

a) Train all machine operators on proper machine handling and safety procedures.
Allow authorized personnel to operate or maintain material handling equipment.
Only those who have been trained to operate and perform maintenance on conveyors
should do so.
b) Do not install the machine near wet or damp areas.
c) Keep hands away from all moving parts at all times, especially from the pneumatic
cylinders, for this may cause harm while at work.
d) Do not wear loose clothing, jewelry, neckties or other garments and accessories that
can become entangled with moving parts on the machine. Long hair must be tied
back.
e) Do not distract the operator/s while operating the machine.
f) Do not use your hands to remove material from the machine, unless the machine is
turned off.
g) Do not perform service on a conveyor until machine is turned off.
h) Use appropriate personal protective equipment-such as safety glasses or goggles,
respiratory protection and hearing protection.
i) Exercise good housekeeping.
j) Dont step, sit, or stand on the conveyor at any time. It may seem like common sense,
but people frequently do it, and it can lead to serious injury. Our conveyors are not
designed for a humans weight. There are many ways for conveyors to cause injuries
to anyone who sits on them. Aside from the safety factor, this can cause belts to untrack or damage the system.

k) Do not try to remove or alter conveyor guards

l) Do not try to access areas of a machine that have hazardous moving parts while the
machine is running. Call a technician or a maintenance support from AutomaTech if
needed.
m) Never use a machine for anything that it is not designed to do.
n) If any problems arise and cannot be resolved, feel free to contact AutomaTech and we
will be happy to serve.

1.4 System Process

SERIES OF OPERATIONS
A. BOTTLE DETECTION USING SENSORS
Bottles are kept in position in their respective holders which are fixed to the table at
the input side. The sensors are used to detect the presence of bottles in the holder. Depending
on the output of the sensors the filling and capping operation takes place. A time delay is
given in order to set the status of the bottles. If bottle 1 is present the corresponding status bit
in PLC is set to 1 else it is set to 0. The outputs of these sensors are given to the PLC and
depending on this output the filling and capping 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 turn switches ON the corresponding for filling operation to take place. If a
particular bottle is not present the corresponding filling remains OFF.
B. FILLING OPERATION
Once the bottles are detected in the input side the rotating table motor switches ON
and it starts moving in the forward direction. The bottles then reach the desired position for
filling and the table stops. The corresponding filling in process tank switch ON and filling
operation takes place.
C. CAPPING OPERATION
The bottles are transported to the capping arrangement. A limit switch is kept to stop
the bottles in the desired position for capping to take place. Once the bottles reach the
position the table motor switches OFF. The capping of bottles is done using actuator
arrangement. The actuator applies a force on the caps which are placed in their respective
holders. This force helps the caps to fit into the bottles at the required position. Similar to
filling, if a particular bottle is not present it does not get capped. Thus the capping is done and
the conveyor starts moving again. When the capping operation for one batch is done
simultaneously the filling operation for another batch takes place. The entire sequence of
operations continues until there are not bottles present in the input side. All these are
automatically coordinated using the PLC. PLC gets the input from the input devices and

sends the signals to the various output devices depending on the conditions that are fed into
the PLC. Thus bottles get filled and capped.
SUMMARY

A container is manually placed by sliding in the rotating table from an inclined plane.
A sensor is placed before the first station (Filling Station), if the sensor detects no container
the opening of the silo will be closed but the rotation will still continue and an alarm will
warn the operator. After the container is filled, it will pass through the second station
(Capping Station). The cap will be placed automatically after the container pass through it. It
will be followed by the third station (Pressing Station) it will fit the cap to the container. For
monitoring purposes two sensors will be placed in the silo and the cap holder to detect the
amount of caps and candies, if it reaches the critical level the operator will be warned by a
Pilot Lamp.

Section 2. Rationale
Filmatic hold out the ability of timely supply of product and high tech automated
creation. Keeping view of present necessities, this proposes automated bottle filling and
capping process a complete application of the mechanization. A model of this alternative
design controlled using programmable logic controller (PLC) is developed.
Bottle filling system is an application of automation where we developed a bottle
filling system. Here we use a start/stop control of the motor when we on the switch then
motor will be on. Bottles are kept over a rotating table which will be attached with the motor.
When the motor is on rotating table will be start. The filling operation is fixed depending on
how many are need. Filling system has been designed with the help of hardware devices. It
uses dc gear motor drivers, sensing devices, limit switch, Programmable Logic Controller
(PLC) device.

2.1 Abstract
Filling is a task carried out by a machine that packages food products such as candies
or medicines .Traditional methods of bottle filling involved placing bottles onto a
conveyor and filling only one bottle at a time. This method is time consuming and
expensive. Our project aims to fill and cap bottles automatically. The filling and capping
operation takes place in a synchronized manner. The entire system is more flexible and
time saving. The filling and capping operations are controlled using a Programmable
Logic Controllers (PLCS). This is because PLCs are very flexible, cost effective, space
efficient and reduces complexity. By programming the PLC we control the entire system.

2.2 Project Justification

Continuous bottle filling system in food and beverage industry a very common
application is continuous bottle filling system. It is most important application in whole plant,
where bottles are moving on a rotating table, to be automatically detected and filled by any
candy.
The demand for bottled beverages, medicine pills and candies is very high; people
need the type of products that is compact and handy. This attracts young entrepreneurs in the
world of business, but how can they start without any idea in mass production? The need of
people in making these types of products is very high in cost and is not recommended when
starting a new business.
These types of machines will cut the cost of entrepreneurs in labor cost, increase
production and eliminates the delay in the process. The small investment in PLC controlled
machines will benefit many and will fulfill the needs of people.

Section 3. Project Framework

3.1. Problems / Project Issues and How These Were Resolved
Our project is not easy for us starters who are just starting to learn. Theres been many
problems occurred while doing the project especially when it comes to the color of the
project we will make, the design and everything. We had a problem with the control box
because of the thickness of the wood. So we have to chip some part of, we even remove the
wirings so we have to start over again in connecting the wires in the control box. We also
struggle in the motor and the wheel that it spins because it does not stops immediately when
the motor stops, so we have to change the extension spring so that the wheel will stop
immediately as the motor stops. We also did change the silo because it you cant see what is
inside the silo so what we did is we find for a better replacement. These are the major
problems we encounter while doing the project, some are minor that we managed to solve it
immediately.

3.1.1 Planning and Methodology

It can only fill approximately one bottle at a time. The process can be efficiently used
in food filling system. Positioning the solenoid valve is a critical issue and proper care is
needed.
Bottles are kept in position in a slider over a rotating table; they are sensed to detect
their presence. The sensors are used for sensing the bottles. Depending on the output of the
sensor the corresponding filling switch on and filling operation takes place. If the particular
bottle is not present then the filling in that position is switched off, thereby avoiding wastage
of the food. The filling operation is accompanied with a user-defined volume selection menu
which enables the user to choose the volume of food to be filled. The filling process is done

based on timing. Depending on the preset value of the timer the filling is switched on for that
particular period of time and the filling is done.

3.1.2 Project Assembly

3.1.2.1 Rotating Table
Illusion

Actual

3.1.2.2 Stations

3.1.2.3 Slider

3.1.2.4 Panel

3.1.3 Designing
3.1.3.1 PLC Symbolic Addressing

Symbol

Address

START
STOP
SWITCH
SENSE
SWITCH
SWITCH

I0.0
I0.1
I0.2
I0.3
I0.4
I0.5

MOTOR
CYL_A
CYL_B
CYL_C

Q0.0
Q0.1
Q0.2
Q0.3

Comment
INPUTS
Normally Open Pushbutton
Normally Open Pushbutton
Normally Open Switch
Normally Closed Proximity Sensor
Normally Open Switch
Normally Open Switch
OUTPUTS
24 VDC Motor
24 VDC Solenoid (SOL_A)
24 VDC Solenoid (SOL_B)
24 VDC Solenoid (SOL_C)

3.1.4 PLC Ladder Diagram

3.1.4.1 Main

3.1.4.2 Motor

3.1.4.3 Filling

3.1.4.4 Capping

Section 4. Materials & Equipment

4.1 Essential Materials for the Project
Material

Specifications / Description

Supplier

1.Electric Motors
2.Pneumatic
Cylinders
3. Sensors

4.Programmable
Logic Controller

5.Pneumatic Hose
6.Pneumatic
Fittings
7.Plywood
8.Pushbutton
9.Electrical Wire
10.Nails and
Screws
11.DC Supply
12.Solenoid Valves
13. Pilot Lamp
14. Silo
15. Bottles
16. Bolts and Nuts
17. Limit Switch
18. Bearing

19. Polyester

Torque: 8-200rpm
Supply: 6-24VDC
Type: Double Acting
Supply: 0 10 bars
Stroke: 100 and 150mm
Type: Proximity
Sensing Range: 0mm to
12mm
Supply:
10VDC
to
30VDC
Type: Non-Shielded
Brand: Siemens
Model: S7-200
Supply: 220 VAC
Output: 24 VDC
6mm diameter
6mm diameter
Base: 15x15cm
SPST, Normally Open, 3.3 cm
diameter
4 mm
1 inch
24 VDC
24 VDC, Monostable
24VDC
11 inches
Diameter: 3 inches
Height: 2-3 Inches
Length: 4cm
Diameter: 10mm
250VAC
9 balls, outside diameter
29mm/1.14", inner
diameter 17mm/0.67" for
bottom brackets. 3 piece
cranks
1 liter
Polituff

20. Spray Paint

Raon
Raon
MFI Technological Institute

MFI Technological Institute

MFI Technological Institute

eGizmo Mechatronix Central
Inc.
Donated
Deeco
Deeco and MFI
Technological Institute
MFI Technological Institute
MFI Technological Institute
MFI Technological Institute
H. Lukban Auto Supply
Donated
Donated

Rush Import & Marketing

Inc.

RJ Supreme Paint Co.

RJ Supreme Paint Co.

Size: 400 cc
Packing; 1x 12 cans

21. Abrasive Paper

22. Palette
23. Cable Tie
24. Corner Plate
25. Angle Bar

26. Computer
27. Funnel

1.

2.

3.

9" x 11"
4 inches
2.5 x 80 mm
Thickness: 0.6mm
Edge width: 20mm60mm
Thickness: 1mm-2mm
Length: 8-10 ft
Personal Computer
Type: Plastic

RJ Supreme Paint Co.

RJ Supreme Paint Co.
Deeco
Donated
Donated

MFI Technological Institute

4.

5.

6.

7.
8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.
22.

23.

24.

25.

26.

27.

4.2 Tools & Equipment Used

Tool / Equipment
1.Hand Drill

2.Digital
Multimeter
3.Hack Saw
4.Pliers
5.Hammer
6.Measuring Tape
7.Soldering Iron
and SolderingLead
8.Packaging Tape/
Super Glue
9.Caliper
10.Files
11. Cutter
12. Tweezers
13. Screwdriver

1.

2.

Description
Brand: Black & Decker
Model: CD50
Supply: 220 VAC
Brand: Sanwa
Model: CD772
305mm
Types: Diagonal cutting plier
Long nose plier
Types: Ball-peen,
Rubber Type
16 ft 5m
Supply: 220 VAC
Brand: Mighty Bond (Super Glue)
Brand: Mitutuyo
Type: Round and Half-round Files
Knife Type: Snap Off
Blade Material: Stainless Steel
Brand Name: Stanley
Model Number: 94-156
Type: Philip and Flat

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

Section 5. Project Outcome

Section 6. Project Conclusion

The main objective of this paper was to develop a bottle filling and capping system
based on certain specifications. This was successfully implemented. We consider this paper as
a journey where we acquired knowledge and also gained some insights into the subject which
we have shared in this report. PLC was used to control the various. More features can be
added to this system as follows: depending on the size, shape and weight of the bottles, filling
and capping operations can be implemented. Capping operation can be improvised using a
piston arrangement.
PLC based Bottle filling 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 theres need for
increased production. The programming of this system is flexible, quickly and easily done.
This will increase the total production output; this increase in production can yield significant
financial benefits and savings. This system is very useful for future with the help of this
system; more features can be added to this system as follows: depending on the size and
shape of the bottles, filling operations can be implemented. Capping operation can also be
implemented. This concept can be used in food industries, milk industries, medicine
industries, mineral water, chemical product industries and manufacturing industries.