International Journal of Current Engineering and Technology E-ISSN 2277 – 4106, P-ISSN 2347 – 5161

©2016 INPRESSCO®, All Rights Reserved Available at http://inpressco.com/category/ijcet

Research Article

Design and Development of Cost Effective Automatic Machine for

Powder Packaging
M. R. Saraf†*, V. V. Ruiwale†, V. V. Kulkarni† and S. M. Kulkarni†
†Mechanical Engineering Department, MITCOE, Sri Savitribai Phule Pune University, Pune, Maharashtra, India

Accepted 02 March 2016, Available online 15 March 2016, Special Issue-4 (March 2016)

Abstract

The packaging industry has advanced leaps and bounds over the few years. The pouch packaging machines also
known as Form Fill and Seal Machines (FFS Machines) are available over a wide capacity range. A low cost
automated packing machine can be used by small enterprises which would help reduce their cost of plant. This low
cost automated machine uses simple pneumatic, mechanical and electric systems. In this paper we have presented
one such low cost pouch filling machine. An additional weighing and pouring mechanism has been added to increase
the accuracy of the system. The process flow has been described in detail. Various processes involved in the pouch
packaging are neatly aligned and properly timed to get optimum production rate. A mechatronics system, developed
for this machine, which takes feedback from sensors and accordingly controls the manipulators has been introduced
in this paper. A microcontroller system is used for this particular machine. A detailed cost comparison between a
conventional machine and the one developed by us has been presented.

Keywords: Low Cost Automation, Microcontroller, PLC

1. Introduction
1 Inthe current global scenario better quality, low cost
with higher productivity are major factors for any
enterprise to flourish. To cope up with the ever
increasing market competition, low cost automation is
the safest strategy. Low Cost Automation comprises the
use of standard components to mechanize or automate
machines, processes and systems. These low cost
automated machines can be operated by semi-skilled
or unskilled labors as it requires limited human
intervention. In this paper need of automation, types of
automation, design, process flow and cost comparison
have been described.
2. Literature Review

Pouch packing machines are commonly known as

Form Fill and Seal Machines. There are classified as
two main types– Vertical Form Fill and Seal Machines
and Horizontal Form Fill and Seal Machines. Vertical
Form Fill and Seal Machines (VFFS Machine) are used
to pack regular shaped solid products or liquids while,
Horizontal Form Fill and Seal Machines are used to
pack irregular shaped products. In this paper we focus
on the Vertical Form Fill and Seal Machines. VFFS
machines are widely used in most of the industries to The VFFS Machines are again classified in two ways-
pack products of various sizes (depending on their According to their type of motion (Continuous motion
weights). and Intermittent motion) and According to their type
of automation (Fully automated and Semi automated).
*Corresponding author: M. R. Saraf In making of the pouch two seals have to be made
420| MIT College of Engineering, Pune, India, AMET 2016, INPRESSCO IJCET Special Issue-4 (March 2016)
Mangesh et al Cost Effective Automatic Machine for Powder Packaging

horizontal and vertical as it will be further explained in operation are typically stored in battery-backed-up or
detail. Intermittent motion machine makes the vertical non-volatile memory. Microcontroller is commonly
seal while the film is in motion but for the horizontal used term for a small computer on a single chip, which
seal the film stops whereas, the continuous motion contains the microprocessor, memory and other
machine makes the vertical and the horizontal seal accessories. Microcontroller has reduced size and price
without stopping the film. Hence, higher production in comparing with other devices. Microcontrollers very
rates can be achieved by the continuous motion frequently have amount of accessories like analog-to-
machine. On the other hand, Fully automated machine digital converter, digital-to-analog converter,
requires no human intervention while Semi automated programmable timer and counter etc. Powerful and
machines require humans to perform some part of carefully chosen electronics embedded in the
packing operation. The machine discussed in the paper microcontrollers can
can be classified as an intermittent motion machine or
fully Automatic machine.

3. Need of Automation

Pouch packing involves a number of steps like bag

forming, weighing, and sealing the bag. If all these
processes are to be done manually, the time required is
more. The production rates will be slow. In order to
achieve higher production rates use of automated
machines is necessary. Automated machines are time
savvy which gives the entrepreneurs to gain a
competitive edge. The quality of the work is high and is
repetitive. Automated machines can help reduce the
waste generated hence, leading to proper utilization of
the resources. Workers may suffer from fatigue which
might lead to improper job quality. Use of an
automated machine lessens the labour dependency of
the enterprise. The key to achieve all of the above
stated advantages while keeping the cost to be
minimum is Low Cost Automation. PLC requires programming software, PLC control
console and a computer to operate, whereas a
3.1 Types of Automation Techniques microcontroller combined with some accessories can
complete the job of automating a machine.
A pouch packing machine can[2] be automated in
different ways. The three main types of automation
techniques are Relay Logic control, Programmable
Logic Control (PLC) and Microcontroller technique.
Relay Logic Control uses relays interconnected to each
other by wires to operate. A relay logic control panels
are very large, sometimes large enough to occupy a
wall. The life of a relay is limited so some of them need
to be replaced, in order to replace a relay the machine
needs to be stopped and eventually the production. To
discover an error is very tedious as it is a very complex
system. Electricians need to be very skillful in finding
errors. The control system is very inflexible so changes
cannot be done easily. Due to all such reasons, relay
logic control is obsolete.
A Programmable Logic Controller, PLC or
Programmable Controller is a digital computer used for
automation of electromechanical processes, such a
control of machinery on factory assembly lines,
amusement rides, or light fixtures. PLCs are used in
many industries and machines. Unlike general-purpose The cost of PLC control is more than that of a
computers, the PLC is designed for multiple inputs and microcontroller unit. PLCs are more flexible than
output arrangements, extended temperature ranges, microcontroller units but in this case, flexibility
immunity to electrical noise, and resistance to required is very less. Due to all such reasons, the
vibration and impact. Programs to control machine microcontroller technique is much more suitable to
421| MIT College of Engineering, Pune, India, AMET 2016, INPRESSCO IJCET Special Issue-4 (March 2016)
Mangesh et al Cost Effective Automatic Machine for Powder Packaging

achieve Low cost automated packing machine. Hence,

in this case microcontroller technique is used.

4 Principle of the System

The material is fed into the hopper whichis situated on

top of the machine. The hopper has a pipe attached to it
at the bottom through which the material passes. The
pipe has a flap arrangement to allow or prohibit the
further flow of the material. The flap is actuated by a
pneumatic cylinder, when the flap is open the material
falls into a bowl. A load cell is placed beneath the bowl
to measure the weight of the material falling in it. [4]

Heat sealers are mounted vertically and horizontally to

make vertical and horizontal seals. Two horizontal
sealers are placed to make the bottom and top seals of
the pouch. These heat sealers are actuated by
pneumatic cylinders. A set of draw rollers are mounted
vertically on the forming tube which pull the formed
plastic downwards. These rollers are rotated with the
When a specific amount of material falls into the bowl, help of a motor. A cutter is placed between the
flap is closed and the bowl rotates thus emptying it into horizontal seals to separate two consecutive bags from
the forming tube. The forming collar shapes the flat each other.
film into a round film tube. Low friction rollers guide
the film to the forming area and maintain tension in the 4.2 Process Flow
film thus preventing it from slagging. Vertical heat
sealers seal the edges of the round film tube. Draw
rollers pull the bag downwards after the vertical seal
has been done which also unwinds the plastic film from
the roll. Cross sealing jaws create top and bottom seals
in the pouches. A cutter separates the pouches which is
placed between the cross sealing jaws. Finally, an
accurately weighed pouch is made.
4.1 Machine Layout

In the design shown above, a separate weighing

mechanism is added. Load cell arrangement allows for
accurate measurement of the material to be filled in the
pouch. Load cell arrangement allows for accurate
measurement of the material to be filled in the pouch.
When the bowl is filled with the specific amount of
material, it rotates and the material falls in the forming
tube. A pneumatic cylinder and disc arrangement
rotates the bowl. The forming collar is a uniquely
designed structure by which the flat plastic film is
turned into a vertical round film.
422| MIT College of Engineering, Pune, India, AMET 2016, INPRESSCO IJCET Special Issue-4 (March 2016)
Mangesh et al Cost Effective Automatic Machine for Powder Packaging

Cost Comparison

Table 1 Cost Comparison between Various Systems

423| MIT College of Engineering, Pune, India, AMET 2016, INPRESSCO IJCET Special Issue-4 (March 2016)
Mangesh et al Cost Effective Automatic Machine for Powder Packaging

The system is divided in four main mechanisms A faster and more complex cup filler and feeder
Forming mechanism, Feeding mechanism, weighing mechanism can be used so as to save time and obtain
mechanism and sealing mechanism automated by a volumetric accuracy of the pouch to be filled. The
microcontroller unit. Some of the mechanisms or system can be scaled against heavy loads.
operations are executed simultaneously. As shown in
the diagram, the forming and feeding mechanism occur Conclusions
simultaneously as well as weighing and vertical sealing
occur simultaneously. The top and bottom seals are Using currently available information and data on
done at the end. flexible automation techniques and mechatronics
systems the automation of the machine has been
4.3 Algorithm
developed. Due to a simple design and the use of low
The process algorithm explains the working of the cost reliable components, the machine is developed in
system in detail. The material is initially fed in the lesser cost as compared to other conventional
hopper. The flap is opened by the pneumatic cylinder machines. Hence, the Low cost automated Pouch
arrangement, the material falls in the rotating bowl Packing Machine is successfully developed which can
which is measured by the load cell. The load cell sends benefit small Industries or enterprises. Safety of the
a signal to the microcontroller after a fixed amount of workers is achieved as the machine requires very less
material falls in to the bowl. The microcontroller
human intervention.
immediately closes the flap. The signal to heat sealer
piston is sent, the piston actuates and the heat sealer
makes the vertical edge seal and the horizontal seal of References
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mechanisms- Feeding, Weighing, Forming and Sealing. http://www.mikroe.com/old/books/plcbook/chapter1
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424| MIT College of Engineering, Pune, India, AMET 2016, INPRESSCO IJCET Special Issue-4 (March 2016)