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Nitish Sharma,
Sagar Bharti,
Mr. Nikhil Bajpai,
Lalbabu Ram,
- Student, Department of MechanicalEngineering Bansal institute of Enginnering Technology Lucknow, Uttar Pradesh, India
- Student, Department of MechanicalEngineering Bansal institute of Enginnering Technology Lucknow, Uttar Pradesh, India
- Assistant Professor, Department of MechanicalEngineering Bansal institute of Enginnering Technology Lucknow, Uttar Pradesh, India
- Student, Department of MechanicalEngineering Bansal institute of Enginnering Technology Lucknow, Uttar Pradesh, India
Abstract
Filling is an important process of the automatic machine and is used in different
industry such as mineral water, beverage, chemical, food and dairy as well as pharmaceuticals. In today’s
manufacturing environment, with the need for higher production rates, better product quality and less
manual effort, industrial automation is becoming a key requirement. The primary goal of this project is
to design, develop and control an automatic bottle filling and capping system using Programmable Logic
Controller (PLC). The aim of this system was to determine the accuracy and efficiency of the automation
of detection, filling and capping of bottles with more precision. Prototype model has been fabricated to
verify the working principle of system in a controlled environment. The PLC is the master controller and
controls all the operations as programmed in the ladder logic. The conveyor belt is powered by a DC
motor, which ensures a smooth and efficient movement of the bottles between the different loading
stations. The proximity sensors are able to locate the position and presence of the bottles in order to fill
and cap them exactly, thus minimizing waste. The PLC’s are programmed using one of the most
common and easy to use industrial automation programming languages, that is, the ladder logic. The
developed system has the following advantages: low power consumption, low operating cost, low
maintenance, high reliability, repeatability and high production efficiency. The prototype is also an
excellent learning and training instrument to better understand the concepts of PLC based automation
system and its application in bottle filling and bottle capping process.
Keywords: PLC, Industrial Automation, Bottle Filling, Bottle Capping, Conveyor Belt, Proximity Sensor, DC Motor, Ladder Logic
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| Volume | 04 | |
| 02 | ||
| Received | 17/07/2026 | |
| Accepted | 17/08/2026 | |
| Published | 20/08/2026 | |
| Publication Time | 34 Days |