Universal Review ISSN NO : 2277-2723

Software Implementation of Automatic bottle filling using PLC

for Industries
Kanishak Sharma#1, Dr. Sangeeta Kamboj*2
#
Student, Electrical and Instrumentation Engineering department,
Thapar Institute of Engineering and Technology, Patiala
*Assistant Professor, Electrical and Instrumentation Engineering department,
Thapar Institute of Engineering and Technology, Patiala
1
kanishaksharma13@gmail.com
2
sangeeta.kamboj@thapar.edu

Abstract— The application of PLC and SCADA is widely known for industrial application to control
a mechanical movement in order to create an efficient production. For rapid industrial growth in
developing countries like India which is basically a nucleus of small industries, it is of primary
importance to put wheels of efficiency of these small industries properly geared to accelerate
productivity. In the paper, Programmable Logic Controller (PLC) and Supervisory Control And Data
Acquisition (SCADA) based system has been designed to automate multiple processes present in a
bottle filling plant. The simulation studies of the designed system for cleaning, sorting, filling and
packing of bottles are also presented in the paper. System designed is also provided with security
features for different levels of authorization. The implementation of the designed system in real time
can be very useful for small scale industries to automate their plants.

Keywords: PLC, SCADA, Bottle filling automation, TIA portal, Simulation.

I. INTRODUCTION
Modern day industries rely heavily on automation. Automation uses control systems and information
technologies to reduce the need for human work in the production of goods and services. It is process
of delegating human controls to machines. In the scope of industrialization, automation is a step beyond
mechanization. Where mechanization provides human operators with machinery to help them with the
muscular requirements of work, Automation greatly decreases the need for human sensory and mental
requirements as well [1]. Automation plays an increasingly important role in the world economy and in
daily experience. Some limitations of mechanization are lack of flexibility, Difficulty in adapting to
frequent changes in market condition and Needs skilled manpower.
Some of the reasons of automation include shortage of labor, high cost of labor, increase in
productivity, increase in quality of production, reduced downtime and increase in safety of workers in
hazardous environments. Examples of automation include Industrial robots, automatic material
handling, feedback control system, process control system and so on.
Automation is utilized for all control systems and the innovations in PLC is use to diminish the
human work and aides in expanding the production. PLC assumes an essential part in the world of
automation industry [2]. It acts a noteworthy function in the automation field which tends to diminish
the complexity, expands safety and cost effective. It is very flexible and can be reapplied to control
other system easily and quickly. Since the troubleshooting of PLCs is becoming faster day by day they
also largely decrease the downtime of a plant. A Programmable logic controller (PLC) is essentially a
PC frequently utilized as a part of commercial and industrial applications. These differ from the

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workplace PCs in the sorts of assignments performed and equipment/programming utilized by them.
All PLCs screen inputs, process the information in view of stored program, and control yield to
automate a machine or process. User defined selection volume in percentage is achieved with PLC on
a bottle filling system which uses the ladder language. Ladder logic is used to control the process [3].
Supervisory Control and Data Acquisition (SCADA) shows a PC framework for gathering and
examining continuous information. All things considered, it is a simply programming bundle that is
situated over hardware to which it is interfaced, in general by means of Programmable Logic Controllers
(PLCs), or other commercial hardware modules [4]. SCADA systems are utilized to screen and control
a plant or hardware in industries, for example, broadcast communications, water and waste control,
energy, oil and gas refining and transportation. The SCADA framework assembles data, for example,
where a break on a pipeline has happened, exchanges the data back to a central site, cautioning the home
station that the leak has happened, completing vital investigation and control, for example, deciding
whether the leak is critical, and showing the data in a legitimate and sorted out form. SCADA
frameworks are utilized not just in industrial processes: e.g. steel making, power generation (traditional
and atomic) and distribution, but also in some experimental facilities, for example, atomic fission. The
size of such plants extends from a couple of 1000 to a few 10 thousands input/output (I/O) channels.
SCADA frameworks can be simple, for example, one that screens environmental conditions of a small
office building, or highly complex, for example, a system that screens all the action in an atomic power
plant or the activity of a municipal water system.
Some of different ways in which bottle filling can be achieved are discussed in several different
research papers. According to one of the research paper [5], a system has been designed in which DC
motor was used to control the conveyor system. Push button and toggle switch were used which to act
as the input to the PLC. The only limitation of this system was that it could only fill few bottles in a
minute.
Another machine of automatic bottle filling and capping has been designed as prototype in the reference
[6]. Most of the available literature on automatic bottle filling show filling and capping sections of bottle
filling and do not work on other processes involved in it.
The paper presents the modelling of multiple processes involved and gives a final system which can
be installed on a PC system with the requirement of Siemens softwares. The programming for the
system has been developed and done on the PLC S7-300 through the use of Totally Integrated Portal
(TIA portal) . The SCADA system is used to control and monitor the performance of the designed
system.

II.METHODOLOGY

All the processes are controlled by ladder logic of PLC and are monitored on SCADA by providing
appropriate movements/animations. Each process of the designed system is also controlled by using
one or more timer functions. Due to similar inputs for timer, a function block is created which helps in
decreasing the length of ladder logic and makes the logic easier to understand.
The following steps has been used for interfacing in TIA portal to establish a connection between PLC
and SCADA:
1. Add desired PLC to the system. ( S7300 PLC in this case )
2. Add desired SCADA system (PC system).
3. Under network view connect both PROFINET ports present on PLC and PC system by drag and drop.
4. Under connections drag and drop on same ports again to establish a HMI connection as shown in figure
1.

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5. After the connection has been set up assign different IP addresses to PC system and PLC as shown in
figure 1.
6. The IP address of PC system must be same as that of running PC in order to access hard disc.
7. Change the access point to PLCSIM.TCPIP.1 and uncheck set automatically under connection
parameters.
8. Save the project and download configurations to PLCSIM.
9.

Figure 1: Connection view of added devices

After the connection between PLC and SCADA has been set up ladder logic of PLC can be written
under main organization block (OB). Length of logic can be decreased by using function blocks for the
similar types of inputs and outputs which are used repeatedly. For completion of this simulation project
multiple inputs were used to resemble sensor inputs in real life situations. Logic consists of multiple
normally open switches, normally closed switches, output coils, memories, timers and counters.
SCADA interface is designed on HMI screen view in WinCC RT professional. Following steps are
followed to design required GUI interface:
1. Add required number of screens to your project.
2. Define a particular screen as start-up screen.
3. Under services of runtime settings enable data logging if storage of data is needed.
4. In editor window on the right side of screen toolbox contains all the required basic objects, elements,
controls and graphics.
5. To change the sequence of layers added in form of objects or graphics go to layout on rightmost part
of screen and arrange the layers as needed. The object shown at the most bottom is shown at the top in
the designing screen.
6. After all the objects have been added on screen >> select all objects >> right click and click >>
dynamization overview. It is used to change response time of simulation.
7. Set the dynamization time as per requirement, it ranges from upon change to 1 hour.
8. Go to history data >> add new data log >> add new logging tags. (only needed for data logging)
The flow chart for SCADA interface has been shown in Figure2.

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Figure 2: Working flow of SCADA system

III SIMULATION STUDIES

Cleaning of bottles

A conveyor system passes the bottles from a cleaning station where empty bottles are cleaned and rinsed
properly before filling process. Start and stop operations can be controlled using SCADA screen as can
be seen in figure3.

Figure 3: Cleaning view on SCADA screen

Sorting of bottles

This process is essential for industries which receive bottles of different sizes from some other supplier,
with the help of a sensor; bottles of different sizes are separated. This process can also be useful to sort
defected bottles from the lot before filling them. In the designed system bottles of small size are pushed
using a pneumatic piston arrangement to different conveyor from which it can be collected in box A
and bottles of large size are allowed to fall into box B as shown in figure4.

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Figure 4: SCADA screen showing sorting process

Filling of bottles

The figure5 shows demonstration of filling of one bottle at a time, it can be extended to a series of
bottles as well. Calculation of time of filling is dependent upon the volume of the bottle. Hence volume
of liquid filled can be controlled by controlling the timer of PLC. For future improvements recipe of
liquids can also be added in SCADA screen to control multiple types of outputs.

Figure 5: Filling as seen on SCADA screen

Packaging

Packing can be done for the required number of bottles per pack depending upon industry requirement.
For demonstration purpose packs of two bottles were made. After two bottles enter the packing machine
they are packed into one box and leave the machine.

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Processes

The figure6 depicts all the running processes of the industry and also shows graphically the production
of industry on time scale.

Figure 6: simulation showing running processes

Connecting code to designed system

While coding the PLC each element and memory is assigned a tag name which is associated with
different properties/events of HMI screen. All the PLC tags can be edited and added in show all PLC
tags option. As shown in Figure 7 each tag has a memory location and data type associated to it.

Figure 7: PLC tags screen

I0.0, Q0.0 and M1.0 addresses are of a single byte and MW4 and MD12 are of data type word (2 byte)
and double word type (4 byte).
In the “HMI screen view” following properties are associated with tags to carry out the complete
process:
 Animation: To provide any sort of movement to objects, tags are associated in animation by giving a
range of value from starting coordinates to some final coordinates.

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 Events: To associate different tasks such as OnClick, OnRightClick, Activate, Release keyboard, etc
with functions like Setbit, Resetbit, Showlogonscreen etc process tags are attached in events.
 Text and graphics list: Process tags are associated with text list or graphic list for different values to
show animation at a static position.

IV. CONCLUSION

The modelling of a automatic bottle filling using PLC and SCADA has been done in the paper. It has
been found that the modelled system can be used to fill series of bottles at a time. The fundamental
reason for PLC in automation is utilized to control the entire system and the major reason for utilizing
SCADA is to monitor process and store data for future improvements. It can be concluded that the cost
of establishment is not cheap but it can effectively keep running for a long stretch of time. In long term
such automated systems can prove profitable for any industry. It can also be concluded that use of level
sensors while filling of bottles may increase efficiency of the system.

ACKNOWLEDGMENT

We would like to extend our sincere gratitude to the faculty of Industrial Automation Training Centre
(IATC), Siemens for providing the required resources to pursue the work.

REFERENCES

[1] A. R. Kiran and B. V. Sundeep, “The principle of programmable logic controller and its role in
automation”, International Journal of Engineering trends and technology, vol. 4, Issue 3, September
2013.
[2] H. M. Malaradhya and K. R. Prakash, “Automatic liquid filling to bottles of different heights using
programmable logic controller”, International Journal of Mechanical and Production engineering,
ISSN 2320-2092, October 2013.
[3] A. U. Abusaed, Md. A. Mamun and A. H. M ZadiduKarim, “Industrial application of PLCs in
Bangladesh”, International Journal of Scientific and engineering research, vol. 2 pp. 2229-2320, May
2012.
[4] Stuart A. Boyer, “Scada – Supervisory Control and Data Acquisition”, International Society of
Automation USA, 4th Edition, 2009.
[5] R. A. Rahimabdul, “Automated multiple water filling (AMWF) machine”. International Journal of
Electronics Communication and Computer Technology, vol. 3, pp. 382-385, 2008-2009.
[6] A. Dakre, J. G. Sayed, E. A. Thorat and A. Choudhary, “Implimentation of bottle filling and capping
using PLC with SCADA”, International research journal of engineering and technology, vol. 2,
December 2015.
[7] Siemens supply, “Simatic S7 manuals and guides”, SITRAIN, Germany, Thirteenth Edition, 2016.
[8] Simatic HMI, “operator control and monitoring system”, SITRAIN, Germany, Fourteenth edition,
2017.

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