MINOR PROJECT SYNOPSIS

ON
AUTOMATIC BOTTLE FILLING USING PLC AND SCADA

DEPARTMENT OF ELECTRICAL AND ELECTRONICS

GURU TEGH BAHADUR INSTITUTE OF TECHNOLOGY
(Guru Gobind Singh Indraprastha University)

Teacher Coordinators :
Ms. Anita Chaudhary
Ms. Gurpreet Kaur

SUBMITTED BY :
Jasreen Kaur Mehta
Manmeet Singh
Deepak Vyas
Himanshu Pruthi

AUTOMATIC BOTTLE FILLING USING PLC AND

SCADA

ABSTRACT
Automation, now a days have become in integral part of the industry, say any production
as well as process industry, it is progressively increasing the productivity and the profitability of
most large organization by rapidly becoming more efficient and competitive by their methods of
production and management. Small industries with small exceptions, is not progressing to the
same extended and their profitability is far too low for stability and growth. The efficiency of
small industries is however, of vital importance to the economy of the country. They represent
90% of all industries, employ about half of those engaged in large industries and produce nearly
half of the manufactured goods.
For rapid industrial growth in developing countries like India which is basically a nucleus
of small industries, it is of primary importance to put the wheels of efficiency of these small
industries properly geared to accelerate productivity, to increase profitability and to achieve this
goal at present juncture is Low Cost Automation as High cost Automation is not within the reach
of developing countries.
SCADA vendors release one major version and one to two additional minor versions once per
year. These systems evolve thus very rapidly so as to take advantage of new market
opportunities.

INTRODUCTION:
PLC
A Programmable Logic Controller (PLC) is an industrial computer centre system that
continuously monitors the state of the input devices and makes decisions based upon a custom
program to control the state of output devices. Almost any production line, machine function or
process can be greatly enhanced using the type of control system. However the biggest benefit in
using a PLC is the ability to change and replicate the operation or process while collecting and
communicating vital information.
Another advantage of a PLC system is that it is modular. That is, you can mix and match the
types of input and output devices to best suit the application.

SCADA
Scada stands for Supervisory Control And Data Acquisition.
It can control the overall action of the system in the field plant. It examines the
status of the input and in responses control the overall process through the output.
Combination of the input and output data are referred to as logic. Several logic
combinations are usually required to carry out program. This program is stored in the
memory and is periodically changed as per the requirements of the party by an order
given to an operator, usually run the programs in predetermined order for SCADA.
Hence, an industrial SCADA system will be used for the development of the
controls of the four experimental terms. This describes the SCADA systems in terms of
their architecture, their interface to the process hardware, the functionality and the
application development facilities they provide. Some attention is also paid to the
industrial standards to which they abide their planned evolution as well as the potential
benefits of their use.

ABOUT THE PROJECT

The technology has been developing even since the Stone Age. The ancient man applied
their minds towards the techniques to have comfort and betterment in their life. The same
phenomenon is continuing even till today.
Always there is tendency and thirsty with human beings to develop a better technique in
any working process to attain or to provide less fatigue and mental stress and more comfort to
the operators. There will be always a desire to-do things in a better way and speedy.
The project AUTOMATIC BOTTLE FILLING PLANT USING PLC AND SCADA is also
based on the above-mentioned as facts. The industries, which are having manual process of
filling, can be automated using Automation & Controlling techniques. Application of
Automation components as per requirement resulted the project of automatically filling and
transporting.

In this plant there are following major operations are performed.

A. BOTTLE DETECTION USING SENSORS
Bottles are kept in position in their respective holders which are fixed to the conveyor at the
input side. IR sensors are used to detect the presence of bottles in the holder. Depending on
the output of the sensors the filling 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 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 pumps

for filling operation to take place. If a particular bottle is not present the corresponding pumps
remain OFF.
B. FILLING OPERATION
Once the bottles are detected in the input side the conveyor motor switches ON and it starts
moving in the forward direction. The bottles then reach the desired position for filling and the
conveyor stops. The corresponding pumps in process tank switch ON and filling operation takes
place. For e.g. if only bottle 1 is present then pump 1 switches ON and pump 2 and pump 3
remain switched OFF. There are three tanks present in the filling side namely: process tank,
concentrate tank (tank 1) and tank to store water (tank 2).Tank 1 and tank 2 have low level and
high level sensors (LLS and HLS) respectively.
Process tank has three level sensors (LLS, HLS and MLS).MLS is used to denote the middle
level of the tank. When the liquid in the process tank reaches below low level (LLS) pumps in
tank 1 and tank 2 switches on and the process tanks get filled. When the level of liquid reaches
high level (HLS) the pumps in tank 1 and 2 switch off.

C. USER-DEFINED VOLUME
The filling operation is accompanied with a user defined volume selection menu. The desired
volume is fed into the PLC and depending on the volume the filling of liquid takes place. The
filling is done using timing operations.
Thus the pump remains on for the preset value of the timer and switches off once time is out.
Once the filling process is done the conveyor starts moving again. Once the bottles reach the
position the conveyor motor switches OFF.