Project Title:

PLC BASED AUTOMATIC INDUSTRIAL FOOD

PROCESSING SYSTEM

Objective:
The project is aimed to meet the following objectives:

To design and implement automated multiple water filling machine

To learn the concept of electrical DC motor system
To apply selector conveyor concept
To implement hardware installation, wiring, mechanical mounting
To learn troubleshooting and analyzing
To learn PLC programming

Many industrial processes are now dependent on automatic machinery. The

transition from manual systems to automatic systems was necessary to
optimize the rate and capacity of production To control an industrial
process, a special microprocessor based controller called the
programmable logic controller (PLC) is used. There are many advantages of
using PLCs in process control. These controllers are built to withstand the
harsh environment of industry floor (i.e. protected against dust, moisture,
hot and cold temperatures etc.), A more attractive feature which made PLCs
so popular is that, the same PLC can be reprogrammed to perform another
task or control another process. Before the introduction of PLCs, electrical
relays were used to automate processes., which were have some

limitations. One of the many uses of PLCs in industries is in assembly lines

involving packaging. Especially in pharmaceuticals, beverage industries,
mineral water packaging plants etc., it is

required to fill-up a bottle with a certain amount of liquid. In these systems,

empty bottles are put on a conveyor belt which brings these to the filling
station. At the station, the bottles are automatically filled-up and then
moved along the conveyor for further stages to perform other tasks such as
cap fitting or packaging etc.

Problem Statement:
This machine is designed to filling of liquid to its
bottle randomly with the help of automatic process control system. This project will reduce the
usage of man power because all of the work will be done by machine. Human held filling
process will cause inexact volume of liquid into the bottle. So using automated system will set
the volume of the liquid exactly the same for each bottle. If all the process is done manually, it
will cost lot of time to complete the task. This machine will also reduce the human error while
doing this process manually.

Design Methodology:
The whole process consists of three tasks:
Filling bottles one after another with the desired level of liquid.
Timely refilling the overhead tank to continue smooth operation.
Controlling of the liquid flow from the reservoir to overhead tank.

Features of this proposed system:

This automatic food
processing system has following features:
Detection of the presence of a bottle using sensor
Timer based automatic bottle filling
Control of the liquid level of the overhead tank

Working Principle:
The design of the system can be divided in to
several parts.
The conveyor belt mechanism to move the bottles from one end of the
assembly line to the other.
The mechanism for accurate positioning of the bottles under the
overhead tank to be filled up by liquid.
The mechanism for controlling the flow of liquid to the bottle.
The liquid level maintaining mechanism at the overhead tank.

Major component of the system:

PLC module
Conveyor Belt
Sensor
Motors
Valve
Reservoir

Future Development;
Bottle capping system: This system facilitates the bottle capping
after the liquid is filled. A stepper motor operated capper can be used for
bottle capping.

Robotic arm system: This system can be used to move and place a
bottle to a
required position. It can be used in both placing the bottle on the conveyor
belt and
removing from the conveyor belt to the packaging system.

Packaging system: To box a particular number of bottles the

packaging system can be used. This system can be facilitated by the help of
robotic hand.

Monitoring system: Several monitoring systems can be placed in

this project to
monitor the number and sensing of bottle, quantity of liquid in the bottle etc.