P.E.

S COLLEGE OF ENGINEERING, MANDYA-571401

(An Autonomous Institution under Visveswaraya Technological University, Belagavi)

Mini Project Report On

“ Automatic Bottle Filling System Using PLC”

Submitted By:

PANVITHA H B 4PS21EE029

ABHISHEK B K 4PS22EE400

PRIYANKA 4PS22EE408

SANNA VEERESH 4PS22EE412

UNDER THE GUIDANCE OF

DR.GOPIYA NAIK S
Assistant Professor

Department of Electrical & Electronics Engineering

P.E.S COLLEGE OF ENGINEERING MANDYA – 571401
2023-24

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 P.E.S COLLEGE OF ENGINEERING, Mandya- 571401
(An Autonomous Institution under VTU, Belgavi)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

CERTIFICATE

Certified that the project work entitled “Automatic Bottle Filling System Using Plc”, is a
genuine work carried out by PANVITHA H B, ABHISHEK B K , PRIYANKA, SANNA VEERESH
bearing USN 4PS21EE029,,4PS22EE400,4PS22EE408,4PS22EE412 a bonafide students of P.E.S College
of Engineering, Mandya, in partial fulfillment for the award of Bachelor of Engineering in Electrical &
Electronics Engineering of Visvesvaraya Technological University, Belgaum during the academic year
2023-2024. It is certified that all the corrections/suggestions indicated for Internal Assessment have been
incorporated in the report deposited in department library. The project report has been approved as it
satisfies the academic requirements in respect of project work prescribed for the said Degree

Signature of the Guide Signature of the HOD

DR.GOPIYA NAIK S Dr. KMMAHESH KUMAR
Assistant Professor Head Of the Department
Dept. of E&EE Dept. of E&EE
PESCE ,Mandya PESCE, Mandya

EXTERNALVIVA
Name of examiner Signature with date
1)
2)

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Automatic Bottle Filling System Using Plc 2023-24

ACKNOWLEDGEMENT

It is my great fortune that I have got opportunity to carry out this project work under the
supervision of Prof. (Dr.) GOPIYA NAIK S in the Department of Electrical Engineering,
PESCE mandya, affiliated to Visveswaraya Technological university, belagavi .our sincere
thanks and deepest sense of gratitude to my guide for his constant support, unparalleled
guidance and limitless encouragement. I wish to convey my gratitude to Prof. (Dr.)
MAHESH KUMAR K M HOD, Department of Electrical Engineering, PESCE mandya .For
providing all kinds of infrastructural facility towards the research work. I would also like to
convey my gratitude to all the faculty members and staffs of the Department of Electrical
Engineering PESCE for their whole hearted cooperation to make this work turn into reality.

Place:
Date:

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DECLARATION

We, Panvitha H B , Abhishek B K , Priyank ,Sanna veeeresh, students of the Electrical &
Electronics Engineering Department at P.E.S College of Engineering, hereby declare that the
project report titled “Automatic Bottle Filling System Using PLC” is an original work carried
out by us during our final year of Bachelor of Engineering. This project has been conducted
under the esteemed guidance of Dr.Gopiya naik S, Assistant Professor at P.E.S College of
Engineering, and with the mentorship and practical support from Shashikiran at Vidyut
Automation. We affirm that this project has not been submitted, either in part or in full, to
any other institution for the award of any degree or diploma. The project work presented here
is genuine and a result of our own efforts and the collaborative effort of our team. We also
declare that all sources of information used in this project have been duly acknowledged.
This work represents our endeavor to contribute to the field of automation engineering and
showcases our academic and practical learning experience at P.E.S College of Engineering

PANVITHA H B 4PS21EE029
ABHISHEK B K 4PS22EE400
PRIYANKA 4PS22EE408
SANNA VEERESH 4PS22EE412

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ABSTRACT

The Automatic Bottle Filling System Using PLC project represents a significant advancement
in automating the bottle-filling process, addressing common challenges in efficiency,
accuracy, and operational consistency. The system is designed to automate the entire filling
procedure by integrating Programmable Logic Controllers (PLCs) with various sensors and
actuators, offering a comprehensive solution for industrial and commercial bottling
applications.

At the core of the system is the PLC, which manages the real-time control and monitoring of
the filling process. This includes the detection of bottle presence, precise control of fill levels,
and the coordination of capping operations. The system is equipped with sensors that detect
the position and size of bottles, ensuring that each container is filled accurately without
manual intervention. Actuators are used to control the flow of the liquid and the movement of
bottles through the filling station.

The project demonstrates the system’s capability to handle various bottle sizes and types,
making it versatile and adaptable to different production requirements. By automating the
filling process, the system reduces human error, minimizes product wastage, and enhances
overall operational efficiency. The PLC-based control system ensures that each step of the
process is executed with high precision, leading to consistent fill levels and improved product
quality.

Additionally, the project includes a user-friendly interface for monitoring and controlling the
system, providing real-time feedback and diagnostics. This feature allows operators to easily
adjust settings and troubleshoot issues, contributing to smoother operation and reduced
downtime.

Overall, the Automatic Bottle Filling System Using PLC project provides a reliable, scalable,
and cost-effective solution for modern bottling operations, aligning with industry standards
for automation and quality assurance.

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CONTENTS
ACKNOWLEDGMENT
DECLARATION
ABSTRACT

SL.NO CHAPTER NAME PAGE NO

01. INTRODUCTION 7

02. PLC AND LADDER DIAGRAM 8

03. BLOCK DIAGRAM 9

04. LADDER DAIGRAM FOR THE PROJECT 10-11

05. METHODOLOGY 12

06. SCHEMATIC GIAGRAM 13

07. HARDWARE DESCIPTION 14-21

08. FLOWCHART 22
09. RESULT AND DISCUSSION 23-24

10. CONCLUSION 25

REFERENCE 26

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CHAPTER-1
INTRODUCTION

Project Title: Automatic Bottle Filling System Using PLC.

The efficient and consistent filling of bottles on a conveyor system is a critical aspect of
many manufacturing processes. A crucial component in this process is the water tank, which
provides the necessary water supply for filling. Maintaining a stable water pressure within the
tank is essential to ensure accurate and uniform filling of the bottles. Fluctuations in water
pressure can lead to inconsistencies in fill levels, product quality issues, and decreased
production efficiency.

This project focuses on the development and implementation of a system designed to

maintain a constant water pressure within the tank used for filling bottles on a conveyor. By
effectively regulating the water pressure, the system aims to enhance the overall efficiency
and reliability of the bottle filling process.
The subsequent sections of this report will delve into the system's design, components,
implementation, and performance evaluation.

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CHAPTER-2
PLC & LADDER DIAGRAM

A Programmable Logic Controller (PLC) is a digital computer used for automation

control of electromechanical processes, such as control of machines on factory assembly
lines, robots, automated guided vehicle systems, and other industrial processes. PLCs
combine the ruggedness of hardware with flexible programming capabilities, allowing
them to replace hardwired relay logic control systems.

Ladder logics a programming language used with PLCs. It's also known as a ladder
diagram or LD, and it's one of the most widely-used visual programming languages for

PLCs. The name "ladder logic" comes from its resemblance to a ladder, with two
vertical rails and horizontal rungs. Each rung represents a logical condition.

KEY ELEMENTS OF A LADDER DIAGRAM:

 Rails: The two vertical lines that represent the power supply.
 Rungs: The horizontal l lines connecting the rails ,representing a logical condition.
 Contacts: Represent inputs (like switches, sensors) and can be normally open
(NO) or normally closed (NC).
 Coils: Represent outputs (like motors, lights)and are energized when the rung
condition is met

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CHAPTER-3

BLOCK DIAGRAM

Fig:Block Diagram

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CHAPTER-4

LADDER LOGIC DIAGRAM FOR THE PROJECT

INPUTS: OUTPUTS:

X0=PROCESS START Y0=INLET VALVE

X1=LOW LEVEL SENSOR Y1=OULET VALVE

X2=MAX LEVEL SENSOR Y2=MOTOR

X3=OPTICAL SENSOR

X4=CAPCITIVE SENSOR

X5=STOP PROCESS

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CHAPTER-5

METHODOLOGY

At first, the auto selection switch is selected so that the entire system operates automatically.
Then the “Auto start push button” (toggle switch is used here) is selected and the motor starts
and the conveyor belt starts moving. The DC motor used is a DC geared type motor whose
shaft is coupled directly with the shaft of the roller. This motor has an input voltage of 12v
with an input current of 600mA to 14A.The reason for selecting this motor is to achieve a
high starting torque at a constant speed. It has a torque of 70kgcm.The motor comes with a
metal gearbox and centered shaft. Shaft is loaded with bearing for wear resistance. The
reason for choosing such a high torque is having such heavy rollers used on the either side of
the hardware which is mounted with a conveyor belt. Then two to three bottles is placed
simultaneously on the conveyor belt. Now as the bottle approaches towards the photoelectric
sensor, the sensor senses the bottle and the conveyor stops running. As the conveyor stops ,
the bottle filling process starts . as the bottle fills the capacitive sensor turns on the conveyer
belt starts to move , i.e motor will turn on by the time the optical sensor will be turn off as
soon as the capacitive sensor turns on.
This process will continue along with this as the bottles gets filled the liquid in the tank will
gradually reduces , as soon as the liquid reaches the low level sensor/min switch , it will turn
on and the inlet valve will opens . the inlet valve will be opened till the liquid reaches to the
max switch , once the liquid reached means the max level sensor will be activate the inlet
valve will be closed‘.

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CHAPTER-6
SCHEMATIC DIAGRAM

Fig: schematic diagram

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CHAPTER-7
HARDWARE DESCRIPTION

POWER SUPPLY AND PROTECTION:

The automatic bottle filling system utilizes a Delton MCBC 6 rate dat240VAC as the
main circuit breaker to ensure safety and protection against over current conditions. To
power the PLC and associated components, a 220V AC to 24V DC power supply
module is employed, providing the necessary low-voltage power for the system's
operation.

Fig: MCB

INPUT DEVICES:

Digital-analog input switches are incorporated to provide user interaction with the
washing machine. These switches allow users to select desired wash cycles and other
settings . The PLC processes these inputs to control the washing process accordingly.

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CONTROL UNIT:

DVP14SS2PLCSPECIFICATIONS:
PLC: Delta Number of communication ports:2
Model: DVP14SS2 (comm1:RS232,comm2:
RS485) PWS voltage: 24V DC

I/OVoltage:24VDV PLC type: Modular

Number of inputs: 8 Programming soft ware: WPL Soft2.52
Number of outputs: 6 Programming language: Ladder logic
diagram

Output devices:

To interface with external devices and components, electrical terminal blocks are used
to provide secure connections. And -channel relay car disemployed to control various
loads such as the washing machine motor, solenoid valves, and heating elements.
Additionally, 6 digital outputs are dedicated to controlling indicator lights on the control
panel, providing visual feedback to the user about the washing machine's status

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PLC(Programmable logic controller):

The CPU combines a microprocessor, an integrated power supply, input and output circuits,
built-in PROFINET, high speed motion control I/O and on board analog inputs in a compact
housing to create a powerful controller. After downloading a program, the CPU contains the
logic required to monitor and control the devices in the application. The CPU monitors the
inputs and changes the output according to the logic of the user's program. The CPU provides
a PROFINET port for communication over a PROFINET network.

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PHOTOELECTRIC SENSOR:

Operating voltage is 6 – 36 V DC and its output current is 300 mA. It’s response frequency is
0.5 kHz. It’s output type is n – p – n 3 wire (Black, Blue and Brown). It is made of brass or
plastic. In this project, It is used to sense the position of the bottles. A round shaped sensor is
used which can detect opaque, transparent or any other kinds of objects. In this case it is
detecting different plastic bottles. The sensor used here is a diffused reflective type sensor.
The range of sensing the objects are 100 mm

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DC MOTOR

FIG: DC MOTOR

The DC motor used is a DC motor whose shaft is interconnected with the shaft of the roller.
This motor has an input voltage of 12v with an input current of 600mA to 14A. It’s no load
speed is 50 RPM. The reason for selecting this motor is to achieve high torque at a constant
speed. It has a torque of 70kgcm which provides sufficient amount of torque for our load. The
motor comes with a metal gearbox and centered shaft. Shaft is loaded with bearing for wear
resistance. The reason for choosing such a high torque is having such heavy rollers used on
the either side of the hardware which is mounted with a conveyor belt.

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SWITCH MODE POWER SUPPLY(SMPS)

A switched-mode power supply is an electronic power supply that incorporates a switching

regulator to convert electrical power efficiently. Like other power supplies, an SMPS
transfers power from a DC or AC source (often mains power) to DC loads, such as a personal
computer, while converting voltage and current characteristics. Unlike a linear power supply,
the pass transistor of a switching-mode supply continually switches between low-dissipation,
full-on and full-off states, and spends very little time in the high dissipation transitions, which
minimizes wasted energy. Ideally, a switched-mode power supply dissipates no power.
Voltage regulation is achieved by varying the ratio of on-to-off time. In contrast, a linear
power supply regulates the output voltage by continually dissipating power in the pass
transistor. This higher power conversion efficiency is an important advantage of a switched-
mode power supply. Switched-mode power supplies may also be substantially smaller and
lighter than a linear supply due to the smaller transformer size and weight.

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LEVEL SWITCH:

FIG:LEVEL SWITCH

A level switch is an essential sensor used to detect the amount of liquid, powder, or granular
substance in a container at a specific point. It provides an electrical contact output when the
substance reaches a predetermined level. Level switches play a crucial role in various
applications, from preventing material shortages to controlling pumps and valves.

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CAPCITIVE SENSOR:

FIG:CAPACITIVE SENSOR

A capacitive sensor is an electronic device that detects changes in capacitance between two
conductive surfaces, which can be influenced by the presence of nearby objects or changes in
environmental conditions. These sensors consist of a capacitor, which is typically made up of
two conductive plates separated by a dielectric material. When an object, such as a finger,
comes near the sensor, it alters the electric field between the plates, changing the capacitance.
This variation is then measured and translated into a signal that can be used for various
applications, including touchscreens, proximity sensors, and level sensing in liquids.
Capacitive sensors are valued for their high sensitivity, durability, and ability to function
through non-metallic materials, making them ideal for applications where traditional
mechanical switches would be less effective or more prone to wear. Their versatility and
precision have made them a popular choice in modern electronic devices and systems

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CONVEYOR SYSTEM

 Conveyor belt: A belt of length 2*(3ft.2inches) and width is 3.9 inches. The material
used is PVC. Reason for choosing this belt is has low friction and oil resistant.
 Drive roller

FIG :CONVEYOR SYSTEM

 Drive roller Total net weight of the rollers are 5 Kg. The diameter of the shaft of the
roller is taken 1 inch whereas the diameter of the rollers are 3.5 inches.
 The length of the shaft whose one side is elongated for coupling with the motor is 3
inches. The length of the roller is taken 4 inches.

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FLOW CHART
CHAPTER-8
.
START

STAR NO
BUTTON

MOTOR =ON
CONVEYOR BELT = ON

IS THERE ANY NO
BOTTLE UNDER
THE OUTLET
VALVE?

YES

MOTOR =OFF
CONVEYOR= OFF
OUTLET VALVE
=OPEN

NO
IS THE
BOTTLE
FULL ?

YES

OUTLET VALVE= OFF

MOTOR =ON
CONVEYER BELT = ON

NO
STOP
BUTTON
PUSHED ?

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CHAPTER-9
RESULT AND DISCUSSION
SOFTWARE TEST : According to the working process of the system PLC
programming, Ladder logic diagram(LAD) .simulation software WPL 2.52 is used. PLC
programming in the form of Ladder

The PLC-based automatic bottle filling system successfully automates the bottling process,
ensuring precise and consistent filling of bottles. The system effectively uses sensors to detect
bottle presence and fill levels, activating and deactivating the filling valve as needed. This
automation reduces manual intervention, minimizes errors, and enhances overall productivity.

DISCUSSION:

The implementation of a PLC-based automatic bottle filling system brings several advantages
to the bottling industry. Firstly, the use of sensors for detecting bottle presence and fill levels
ensures that each bottle is filled accurately, maintaining product quality and consistency. This
precision is crucial for meeting industry standards and customer expectations.

Secondly, the automation of the filling process significantly reduces the need for manual
labor, which not only cuts down on labor costs but also minimizes the risk of human error.
This leads to a more efficient and reliable production line, capable of handling higher
throughput and scaling up operations as needed.

Moreover, the flexibility of PLC programming allows for easy adjustments to accommodate
different bottle sizes and production requirements. This adaptability makes the system
suitable for various production scales, from small-scale operations to large manufacturing
units.

In conclusion, the PLC-based automatic bottle filling system is a valuable asset for modern
bottling operations. It enhances efficiency, ensures product quality, and provides scalability,
making it an ideal solution for businesses aiming to improve their production capabilities and
maintain a competitive edge in the market.

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Real-world implementation: Implementing a bottle filling system using a

conveyor belt is a common practice in various industries, especially in beverage and
pharmaceutical manufacturing. Here’s a general overview of how such a system works.

MODEL :

Fig: MODEL

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CHAPTER-10
CONCLUSION

The PLC-based automatic bottle filling system represents a significant advancement in

industrial automation, offering numerous benefits for bottling operations. By leveraging
sensors and actuators, the system ensures precise control over the filling process, which
minimizes human error and reduces labor costs. The integration of a bottle present sensor and
a fill level sensor guarantees that each bottle is accurately filled to the desired level, ensuring
product consistency and quality.

This automation not only enhances productivity by allowing for higher throughput but also
provides scalability, making it suitable for various production scales, from small to large
manufacturing units. The system’s ability to operate with minimal manual intervention
reduces the risk of contamination and increases operational efficiency. Additionally, the use
of PLCs allows for easy programming and adjustments, enabling quick responses to changes
in production requirements or bottle sizes.

Overall, the PLC-based automatic bottle filling system is an invaluable asset in modern
manufacturing and packaging industries. It streamlines the bottling process, improves product
quality, and boosts overall efficiency, making it a cost-effective and reliable solution for
businesses looking to enhance their production capabilities. This technology underscores the
importance of automation in achieving operational excellence and maintaining competitive
advantage in the market.

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REFERENCES
 "PLC Based Automatic Bottle Filling and Capping System With User Defined
Volume Selection “ T.Kalaiselvi , R.Praveena, Assistant professor, Easwari
Engineering College, Chennai. International Journal of Emerging Technology and
Advanced Engineering (ISSN 2250-2459 )2012.

 “Application of PLC for Arranging Bottle in Beer Filling Production Line” ZHANG
Tianxia, DONG Feng , YUAN Hao Tianjin Key Laboratory of Process Measurement
and Control, School of Electrical Engineering and Automation Tianjin University,
Tianjin 300072, China.

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