A Minor Project Report

On

Bottle Filling and Capping System

Using Arduino
__________________________________________________
Submitted to

CHHATTISGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY,

BHILAI

in partial fulfillment of requirement for the award of degree of

Bachelor of Technology
in

ELECTRICAL ENGINEERING
Semester VII
by
NIKHIL PRADHAN, 301302420006, BJ5963
ANAND KUMAR, 3010302420009, BK3377
ANURAG KUSHWAHA,301302420002, BJ5952
VINAY KUMAR AGARWAL,301302420005, BJ5961

Under the Guidance Of

Dr Albert John Varghese

Associate Professor & HOD

DEPARTMENT OF Electrical Engineering,

RUNGTA COLLEGE OF ENGINEERING & TECHNOLOGY,
KOHKA-KURUD ROAD, BHILAI, CHHATTISGARH, INDIA

Session : 2022-2023
 DECLARATION

We, the undersigned, solemnly declare that this report on the project work
entitled “Bottle filling and capping system using Arduino”, is based on
our own work carried out during the course of our study under the guidance of
Dr Albert John Varghese We assert that the statements made and conclusions
drawn are an outcome of the project work. We further declare that to the best of
our knowledge and belief the report does not contain any part of any work which
has been submitted for the award of any other degree/diploma/certificate in this
University or any other University.

Signature

NIKHIL PRADHAN
301302420006
BJ5963

ANAND KUMAR
301302420009
BK3377

ANURAG KUSHWAHA
301302420002
BJ5952

VINAY KUAMR
AGARWAL
301302420005
BJ5961

2
 CERTIFICATE

This is to certify that this report on the project submitted is an outcome of the
project work entitled “Bottle filling and capping system using Arduino”,
carried out by the students in the DECLARATION, is carried out under my
guidance and supervision for the award of Degree in Bachelor of Technology
in Electrical Engineering of Chhattisgarh Swami Vivekanand Technical
University, Bhilai (C.G.), India.

To the best of my knowledge the report...

i) Embodies the work of the student(s) themselves,

ii) Has duly been completed,

iii) Fulfills the requirement of the Ordinance relating to the B.Tech. degree
of the University, and

iv) Is up to the desired standard for the purpose for which it is submitted.

Dr Albert John Varghese

Head of Department of Electrical
Engineering
This project work as mentioned above is hereby being recommended and
forwarded for examination and evaluation by the University,

Dr Albert Varghese

3
 Head of Department of Electrical Engineering,
Rungta College of Engineering & Technology,
Kohka - Kurud Road, Bhilai(C.G.), India

CERTIFICATE BY THE EXAMINERS

This is to certify that this project work entitled “Bottle filling and capping
system using Arduino”.

submitted by…

NIKHIL PRADHAN, 301302420006, BJ5963

ANAND KUMAR, 301302420009, BK3377

ANURAG KHUSWAHA,301302420002, BJ5952

VINAY KUMAR AGARWAL,301302420002

is duly examined by the undersigned as a part of the examination for the award
of Bachelor of Technology degree in Electrical Engineering of Chhattisgarh Swami
Vivekanand Technical University, Bhilai.

Internal Examiner External Examiner

Name & Signature Name & Signature

Date: Date:

4
5
 ACKNOWLEDGEMENT

It is a matter of profound privilege and pleasure to extend our sense of respect and deepest
gratitude to our project guide Dr Albert John Varghese, Department of Electrical

Engineering under whose precise guidance and gracious encouragement we had the
privilege to work.

We avail this opportunity to thank respected Dr Albert John Varghese, Head of the

Department of Electrical Engineering for facilitating such a pleasant environment in the

department and also for providing everlasting encouragement and support throughout.

We acknowledge with the deep sense of responsibility and gratitude the help rendered by
respected Dr. Rakesh Himte, Principal, Rungta College of Engineering and Technology,
Bhilai for infusing endless enthusiasm & instilling a spirit of dynamism.

We would also like to thank faculty members and the supporting staff of Electrical
Engineering department and the other departments in the college, for always being helpful
over the years.

Last but not the least, we would like to express our deepest gratitude to our parents and the
management of Rungta College of Engineering and Technology, Bhilai respected Shri
Santosh Ji Rungta, Chairman, respected Dr. Sourabh Rungta, Director, Technical, and
respected Shri Sonal Rungta, Director, Finance & Administration for their continuous moral
support and encouragement.

We hope that we will make everybody proud of our achievements..

NIKHIL PRADHAN, 301302420006, BJ5963

ANAND KUMAR, 301302420009, BK3377

ANURAG KUSHWAHA, 301302420002,BJ5952

VINAY KUMAR AGARWAL,301302420005, BJ5961

6
 CONTENT
List of Figures………………………………………………………………. 8

List of Table ………………………………………………………………… 9

List of Abbreviation………………………………………………………...
10

Abstract………………………………………………………………………
11

CHAPTER -01 Introduction……………………………………………….

12

1.1 Bottle capping and filling ……………………………….. 12

1.2 Background ………………………………………………
13
1.3 Objective of Project………………………………………
14
1.4 Scope of Project……………………………………………
14
CHAPTER -02 Literature Review………………………………….
15
2.1 Literature Review…………………………………………
15
2.2 Summary………………………………………………….
16
CHAPTER- 03 METHODOLOGY…………………………………
17
3.1 Block Diagram……...…………………………………….
17
3.1.1 Power Supply……………………………………
18

7
 3.1.2 Arduino Uno ……………………………………..
18
3.1.3 Motor Driver Shield………………………………
22
3.1.4 Limit Sensor…………….……………………….
24
3.1.5 conveyor belt ……………………………………...
25
3.1.6 IR Sensor …..………………………………………
28
3.1.7 Jumper Wire………………………………………
29
CHAPTER- 04 Hardware Implementation…………………………
30
4.1 Circuit Diagram………………………………………….. 30
4.2 Assembly of
Hardware…………………………………………32
CHAPTER- 05 RESULT AND
DISCUSSION………………………… 34
5.1
Result………………………………………………………….. 34
5.2
Discussion……………………………………………………... 34
CHAPTER -06 Conclusion and Future
Scope…………………………...36
6.1
Conclusion……………………………………………………..36
8
 6.2 Future
Scope…………………………………………………...36
REFERENCES…………………………………………………………
…38
APPENDIX I(Source Code)
……………………………………………..39
APPENDIX II(Prototype)
………………………………………………..42

9
 LIST OF FIGURES
Figure No Tittle of figure Page No

3.1 Block Diagram of project

3.2 Arduino UNO

3.3 Motor Driver shield

3.4 Proximity sensor

4.1 CIRCUIT Diagram and Explanation

10
 LIST OF Tables
Figure No Tittle of Table Page No

3.1 Digital Pins of Arduino Uno

3.2 Analog pins in Arduino Uno
5.1 Result Table

11
 List of Abbreviation

IR INFRARED RADIATION
I/O INPUT AND OUTPUT
DC DIRECT CURRENT
IC INTEGRATED CIRCUIT
LCD LIGHT CRYSTAL DISPLAY
USB UNIVERSAL SERIAL BUS
GND GROUND

12
 ABSTRACT

This project presents the design and implementation of

a sophisticated Bottle Filling and Capping System using
Arduino as the central control unit. The system aims to
streamline and automate the bottle packaging process,
enhancing efficiency and precision in industries such as
pharmaceuticals, beverages, and cosmetics.
The proposed system comprises two main
functionalities: automated bottle filling and precise
capping. The filling mechanism utilizes sensors to
detect the presence and positioning of bottles on the
conveyor belt, triggering the precise dispensing of
liquid into the containers. Arduino microcontrollers
orchestrate the synchronized operation of pumps,
valves, and sensors to achieve accurate and consistent
filling levels, minimizing waste and ensuring product
quality.
Overall, the proposed Bottle Filling and Capping System
offers an efficient and reliable solution to enhance the
automation of packaging processes. The utilization of
Arduino as the control unit not only ensures precision
and control but also facilitates ease of customization
and future upgrades, making it a versatile and cost-
effective solution for industries seeking to optimize their
production lines

13
 CHAPTER – 01

INTRODUCTION
The bottle filling and capping system represents a pivotal
component in modern manufacturing processes, particularly
within industries such as food and beverage, pharmaceuticals,
and cosmetics. This sophisticated system is designed to
streamline and automate the crucial tasks of accurately filling
containers with liquids or powders and securely sealing them
with precision.

The primary objective of a bottle filling and capping system is to

enhance efficiency, reduce manual labor, and ensure the
consistency and integrity of the packaged product. This system
encompasses various intricate mechanisms and technologies
that work in tandem to deliver a seamless and reliable
packaging solution.

The filling aspect of the system involves the precise

measurement and dispensing of liquids or powders into
containers of various shapes and sizes. This is often achieved
through advanced technologies such as volumetric or
gravimetric filling methods, which ensure accurate and
consistent fill levels.

1.1 BOTTLE CAPPING AND FILLING

A bottle filling and capping system is a vital component within
the realm of manufacturing, offering a sophisticated and
automated solution for efficiently filling containers with liquids
or powders and securely sealing them. This system plays a
pivotal role in diverse industries such as food and beverage,
pharmaceuticals, and cosmetics, where precision, efficiency,
and product integrity are paramount.
The system's core functionality revolves around automating the
traditionally labor-intensive tasks of accurately measuring and
dispensing substances into containers, coupled with the secure
sealing of these containers. To achieve this, advanced
technologies, such as volumetric or gravimetric filling methods,
are employed. These methods ensure precise and consistent fill
14
levels regardless of the container's shape or size, contributing
to the overall quality and uniformity of the packaged products.

The capping aspect of the system is equally crucial, employing

various techniques such as screw capping or snap capping to
securely seal the filled bottles. This not only prevents
contamination but also safeguards the freshness and integrity
of the enclosed product. The integration of automation further
minimizes the risk of errors associated with manual handling,
contributing to increased efficiency and reduced production
costs.

Modern bottle filling and capping systems often incorporate

sophisticated features like sensors, programmable logic
controllers (PLCs), and human-machine interfaces (HMIs). These
elements enable real-time monitoring, control, and adjustment
of the entire process, ensuring precision, reliability, and
adherence to stringent quality standards. This adaptability
makes these systems indispensable for industries striving to
optimize their packaging operations in a competitive market
landscape.
In summary, the bottle filling and capping system stands as a
technological cornerstone, providing a seamless and efficient
solution to meet the evolving demands of modern
manufacturing, where speed, accuracy, and product quality are
paramount.

1.2 BACKGROUND OF BOTTLING

The history of bottling is intricately tied to the evolution
of packaging and the industrialization of beverage production.
The concept of containing and preserving liquids in vessels
dates back thousands of years, with early civilizations using
materials such as clay, glass, and animal hides to store and
transport liquids.

The bottling industry as we know it began to take shape in the

17th century with the invention of the glass bottle. The ability
to mass-produce glass containers revolutionized the
preservation and transportation of beverages. The first
recorded use of a cork as a bottle stopper dates back to the

15
17th century as well, providing a more effective seal than
previous methods.

The real impetus for the modern bottling industry, particularly

in the context of carbonated beverages, can be traced to the
development of carbonation processes and the invention of the
soda fountain in the late 18th and early 19th centuries. The
demand for carbonated drinks surged, prompting the need for
efficient and standardized bottling methods.

One of the key milestones in bottling history occurred in 1892

when the Crown Cork and Seal Company introduced the crown
cap, a metal closure that could be easily crimped onto the top
of glass bottles. This innovation significantly improved the
sealing of bottles, particularly for carbonated beverages, and
became a standard in the industry.

The advent of plastic bottles in the mid-20th century marked

another transformative moment in bottling. Lightweight,
durable, and cost-effective, plastic bottles offered new
possibilities for packaging and distribution. The widespread
adoption of plastic bottles further expanded the reach of bottled
beverages, making them more accessible and convenient for
consumers.

Today, bottling has become a highly sophisticated and

automated process, especially in industries like soft drinks,
water, and pharmaceuticals. Advanced bottling and capping
systems ensure accuracy, efficiency, and hygiene in the
packaging process. Additionally, sustainability concerns have
driven innovations in eco-friendly packaging materials and
recycling practices within the bottling industry.

Overall, the history of bottling reflects not only the

technological advancements in packaging but also the dynamic
relationship between consumer preferences, industrialization,
and the quest for more efficient and sustainable production
methods.

1.3 OBJECTIVE OF PROJECT

The objectives of a bottle filling and capping project can vary
depending on the specific needs and goals of the organization
16
or industry implementing the system. However, common
objectives typically include:

Efficiency Improvement: Streamlining the filling and capping

process through automation aims to enhance overall efficiency.
This can lead to increased production rates, reduced
operational costs, and improved resource utilization.

Precision and Accuracy: The project often focuses on

achieving precise and accurate filling of containers to meet
quality standards and ensure consistency in product packaging.
Accurate capping is also crucial to maintain product integrity.

Cost Reduction: Automation in bottle filling and capping can

contribute to cost savings by minimizing labor requirements,
reducing errors, and optimizing resource utilization. The
efficient use of materials and streamlined processes can lead to
overall cost-effectiveness.

1.4 SCOPE OF PROJECT

The scope of a bottle filling and capping project encompasses a

range of considerations, detailing the boundaries and extent of
what the project aims to achieve. The scope generally includes
the following aspects:

System Design and Implementation: Define the specifications

for the bottle filling and capping system. This involves
determining the capacity, speed, and flexibility requirements,
as well as selecting appropriate technologies, such as filling
methods, capping mechanisms, and automation components.

Technology Integration: Identify and integrate advanced

technologies, such as sensors, programmable logic controllers
(PLCs), human-machine interfaces (HMIs), and other control
systems. Ensure seamless communication and coordination
between different components for efficient and reliable
operation.

17
Product Compatibility: Specify the types of products the system
will handle, considering variations in viscosity, texture, and
other product characteristics. Design the system to
accommodate different bottle shapes, sizes, and materials.

Regulatory Compliance: Define the regulatory standards and

industry-specific requirements that the system must adhere to.
Ensure that the design and implementation comply with safety,
quality, and hygiene standards applicable to the industry, such
as FDA regulations for food and pharmaceuticals.

Operational Procedures: Outline the standard operating

procedures (SOPs) for the bottle filling and capping process.
This includes guidelines for setup, operation, maintenance, and
troubleshooting to ensure consistent and reliable performance.

18
 CHAPTER- 02
LITERATURE REVIEW

Some research paper and article related to the proposed idea

were gone through, some of the key findings from the literature
are highlighted the section below.

2.1 LITERATURE REVIEW

TABLE 2.1 DETAILED LITERATURE REVIEW

Author Year Abstract

Rajesh G. Khatod 2012 The bottle filling system is an

and automated process designed
Chandrashekhar for precision and efficiency in
Sakhle the manufacturing industry.
Employing technologies such
as liquid level sensors, infrared
detectors, and
microcontrollers, the system
ensures accurate filling and
capping of bottles. With a
focus on adaptability, real-time
monitoring, and integration of
IoT principles, this system
represents a modern solution
for streamlined production and
quality assurance in the
bottling industry.

Arthur Pius 2010 The bottle insecticide filling

Santiago and capping machine is an
automated system designed for
efficient and precise packaging
of insecticide products. It

19
 utilizes advanced technologies,
including liquid level sensors
and automated mechanisms, to
streamline the filling and
capping process. The system
ensures accurate positioning of
bottles on the conveyor belt,
precise liquid filling, and
reliable capping, resulting in a
high-speed production process
that optimizes efficiency and
product quality.

Sastry K.N.H 2010 This project introduces a

Srinivas microcontroller-based liquid
mixing system designed for
precision and efficiency in
various industrial and
laboratory applications.
Employing a microcontroller,
such as Arduino, the system
controls the mixing process by
dynamically adjusting motor
speed and liquid dispensing
based on predefined
parameters. The integration of
sensors ensures accurate liquid
measurements, and the user-
friendly interface enhances
ease of operation. This
compact and adaptable
solution offers a reliable
platform for achieving
consistent and controlled liquid
mixing in diverse settings.

Pravin 2018 An automatic bottle filling

Kalubarme, system is a technology-driven

20
Sushil Kumar solution that uses sensors and
Madane, Abhijeet automation to precisely fill
Malve bottles with liquids. This
system improves efficiency,
reduces manual labor, and
ensures consistent fill levels,
contributing to a streamlined
and reliable manufacturing
process.

2.2 SUMMARY
Advanced automation and control systems to optimize the
bottle packaging The automatic bottle filling and capping
project leverages process. Through the integration of
technologies such as liquid level sensors, infrared sensors, and
microcontrollers, the system ensures precise and consistent
filling, reducing manual intervention. The addition of automated
capping further enhances efficiency, resulting in a sophisticated
solution that aligns with modern manufacturing demands for
accuracy and productivity.

21
 CHAPTER -03

METHODOLOGY

The block diagram based on which the proposed idea is

implemented is as discussed below. The basic in the proposed
idea are described in detail.

3.1 BLOCK DIAGRAM OF PROJECT

CONVEYOR
POWER BELT
SUPPLY Arduino UNO

MOTOR DRIVER
SHEILD
LIMIT LIMIT 22

SENSOR 2 SENSOR 1
3.1.1 POWER SUPPLY
The bottle filling and capping project aim to design,
implement, and optimize a sophisticated system for automating
the filling and sealing of containers in manufacturing processes,
with a focus on efficiency, precision, and quality assurance. The
project's key components and objectives can be summarized as
follows:

Efficiency Improvement: Implement an automated system to

streamline the bottle filling and capping process, reducing
manual labor, increasing production rates, and optimizing
resource utilization.

Precision and Accuracy: Focus on achieving precise and

accurate filling of containers through the integration of
advanced technologies, such as volumetric or gravimetric filling
methods, ensuring consistency and quality in the packaging
process.

Cost Reduction: Leverage automation to minimize operational

costs, improve resource efficiency, and enhance overall cost-
effectiveness in the production of bottled products.

Compliance with Standards: Ensure that the system adheres to

industry and regulatory standards, including safety, hygiene,
and quality requirements relevant to the specific industry (e.g.,
food and beverage, pharmaceuticals).

Flexibility and Adaptability: Design the system to accommodate

various bottle shapes, sizes, and product types, allowing for
flexibility in production and the ability to adapt to changing
market demands.

Minimization of Downtime: Implement preventive maintenance

strategies and reliable components to minimize downtime,
ensuring continuous and efficient operation of the bottle filling
and capping system.

Data Monitoring and Traceability: Integrate sensors,

programmable logic controllers (PLCs), and human-machine
23
interfaces (HMIs) for real-time monitoring, control, and
traceability of the entire process, supporting data-driven
decision-making

3.1.2 Arduino Uno

Arduino Uno is an open-source microcontroller board based on
the ATmega328P. It was developed by the Italian company
Arduino and released in 2011 as an entry-level board for
hobbyists, students, and engineers who want to get started with
microcontroller programming and electronics.

Features of Arduino Uno:

1. Microcontroller: The Arduino Uno is based on the

ATmega328P microcontroller, which has a clock speed of
16 MHz and 32 KB of flash memory for storing program
code.
2. Input and Output: The board has 14 digital input/output
pins, 6 of which can be used as PWM outputs and 6 as
analog inputs. There are also 4 built-in LEDs for output.
3. USB Connectivity: The Arduino Uno can be connected to a
computer via a USB port for programming and power
supply.
4. Power Supply: The board can be powered either through
the USB connection or with an external power supply. The
voltage input range is 7 to 20 volts.
5. Development Environment: The Arduino Integrated
Development Environment (IDE) is a free software tool that
can be used to write, upload, and debug code for the
Arduino Uno. It supports several programming languages,
including C and C++.
6. Expansion Shields: The Arduino Uno has a standard form
factor and pin layout, making it compatible with a wide
range of expansion shields, which are boards that can be
stacked on top of the Arduino Uno to add new
functionality.

The Arduino Uno is widely used in a variety of DIY electronics

projects, including home automation systems, robots, and
interactive art installations. Due to its ease of use, low cost, and

24
wide community support, it is a popular choice for hobbyists,
students, and professionals alike.

Fig 3.1 Arduino Uno

The Arduino Uno has a total of 20 pins, which can be divided
into several categories based on their function:
1. Power Pins: There are 4 power pins on the Arduino Uno,
including the +5V, GND, VIN, and AREF pins. The +5V and
GND pins provide a regulated 5V power supply for
powering the board and connected devices. The VIN pin
can be used to supply power to the board from an external
source, and the AREF pin can be used as a reference
voltage for the analog inputs.
2. Digital I/O Pins: The Arduino Uno has 14 digital I/O pins,
which can be configured as either inputs or outputs. Digital
inputs are used to read the state of buttons, sensors, and
other digital devices, while digital outputs can be used to
control LEDs, motors, and other digital devices.
3. Analog Input Pins: There are 6 analog input pins on the
Arduino Uno, labeled A0 to A5, which can be used to read
analog signals, such as the output from a temperature

25
 sensor or a potentiometer. These pins can be used as
digital inputs as well.
4. PWM Output Pins: The Arduino Uno has 6 digital pins that
can be used as pulse-width modulation (PWM) outputs.
PWM is a technique for generating a square wave with a
variable duty cycle, which can be used to control the
brightness of LEDs, the speed of motors, or the
temperature of a heater, for example.
5. Serial Communication Pins: There are 2 serial
communication pins on the Arduino Uno, labeled RX and
TX, which can be used for serial communication with other
devices, such as sensors, displays, or other
microcontrollers.
6. ICSP (In-Circuit Serial Programming) Pins: The Arduino Uno
also has an ICSP header, which can be used to program
the microcontroller on the board using an external
programmer.

In addition to these specific function pins, the Arduino Uno also

has several general-purpose pins that can be used for various
purposes, including digital inputs, digital outputs, analog inputs,
and PWM outputs, based on the requirements of a particular
project.

26
The Arduino Uno has a total of 14 digital input/output (I/O) pins,
which can be configured as either inputs or outputs. Digital
inputs are used to read the state of buttons, sensors, and other
digital devices, while digital outputs can be used to control
LEDs, motors, and other digital devices. The digital pins are
labeled 0 to 13 and are located along the top and bottom edges
of the board.

27
Fig 3.2 Digital Pins of Arduino Uno

28
 The Arduino Uno has 6 analog input pins, labeled
A0 to A5, which can be used to read analog signals, such as the
output from a temperature sensor or a potentiometer. The
analog pins provide a means of measuring analog signals, such
as voltage, and converting those signals into a digital
representation that can be read and processed by the
microcontroller.
An analog signal is a continuous signal that can take on
any value within a specified range, such as a voltage level
between 0V and 5V. In contrast, digital signals can only take on
one of two values, such as high (5V) or low (0V).

29
Microcontroller ATmega328P – 8 bit AVR family microcontroller

Operating Voltage 5V

Recommended Input Voltage 7-12V

Input Voltage Limits 6-20V

Analog Input Pins 6 (A0 – A5)

Digital I/O Pins 14 (Out of which 6 provide PWM output)

DC Current on I/O Pins 40 mA

DC Current on 3.3V Pin 50 mA

Flash Memory 32 KB (0.5 KB is used for Bootloader)

SRAM 2 KB

EEPROM 1 KB

Frequency (Clock Speed) 16 MHz

3.1.3 MOTOR DRIVER SHEILD (LM293D)

A motor driver shield is a type of expansion board for the
Arduino microcontroller board. It provides additional

30
functionality for controlling and driving motors, such as DC
motors, stepper motors, and servo motors.
A motor driver shield typically contains one or more H-
bridge motor drivers, which are integrated circuits that can
control the direction and speed of a motor. H-bridges work by
switching the voltage applied to the motor, allowing it to run in
both forward and reverse directions. By PW Ming the voltage
applied to the motor, the speed of the motor can be controlled.
LM293D Motor Driver
The LM293D is a motor driver integrated circuit that can
be used to control the speed and direction of a DC motor. It is a
dual H-bridge motor driver, which means that it can control two
DC motors at the same time, allowing you to control the speed
and direction of each motor independently.
The LM 293D can handle a maximum current of 1A per
channel, and it has built-in thermal protection to prevent
overheating. It can also be used to drive a variety of other
loads, such as solenoids and relays, by controlling the voltage
applied to the load.
To use the LM 293D in your Arduino project, you will
typically need to connect it to the microcontroller board, such
as the Arduino Uno, and supply it with power. You can then use
digital output pins on the microcontroller to control the speed
and direction of the motor.
The LM 293D is a popular choice for use in motor driver
shields due to its versatility and ease of use, and it is widely
available from electronics suppliers. By using a motor driver
shield that includes the LM 293D, you can simplify the process
of controlling motors in your Arduino projects and focus on
developing the overall functionality of your project.

31
Fig 3.2 LM293D

3.1.4 LIMIT SENSOR

Limit sensors play a crucial role in a bottle filling and capping
system, ensuring precise control over the movement and
positioning of various components. Limit sensors are commonly
used to detect the physical limits of motion along an axis or the
presence of an object in a specific location. Here are some
types of limit sensors that may be used in a bottle filling and
capping system:

Proximity Sensors:
Inductive Proximity Sensors: These sensors detect the presence
of metallic objects without physical contact. They are suitable
for applications where non-metallic objects might interfere with
the sensing process.
Capacitive Proximity Sensors: Ideal for detecting the presence
of non-metallic objects, such as plastic bottles. Capacitive
sensors can work in environments where there might be
moisture or conductive materials.

32
FIG 3.3 PROXIMITY SENSOR
Photoelectric Sensors:
Through-Beam Sensors: Consist of a transmitter and receiver
placed opposite each other. When an object interrupts the
beam, the sensor detects the presence or absence of the
object.
Reflective Sensors: Emit a light beam and use a reflector to
bounce the light back to the sensor. When an object interrupts
the beam, the sensor triggers a response.
Diffuse-Reflective Sensors: Combine the transmitter and
receiver in a single housing. The sensor detects the presence of
an object by measuring the amount of light reflected back.
Mechanical Limit Switches:
Lever Arm Switches: Utilize a lever mechanism that is actuated
by the movement of an object. When the object reaches a
specific position, it triggers the switch.
Plunger or Push Button Switches: Feature a button or plunger
that, when pressed or released by an object's movement,
activates the switch.
Ultrasonic Sensors: Ultrasonic Proximity Sensors: Use ultrasonic
waves to detect the presence of objects. These sensors are

33
suitable for applications where other types of sensors may be
affected by environmental conditions.
Magnetic Sensors:
Magnetic Proximity Sensors: Rely on the detection of changes in
magnetic fields caused by the presence or absence of a
magnet. These sensors are durable and can operate in harsh
environments.
The selection of the appropriate limit sensor depends on factors
such as the specific application, the type of material being
handled (e.g., glass or plastic bottles), environmental
conditions, and the required precision of motion control within
the bottle filling and capping system.
Integrating limit sensors in key positions allows the system to
detect the limits of travel for moving parts, ensuring accurate
positioning and preventing collisions or mishaps during the
filling and capping processes. Proper calibration and
maintenance of these sensors are essential for the reliable and
efficient operation of the overall system.

FIG 3.4 PROXIMITY SENSOR

34
3.1.5 CONVEYOR BELT
A conveyor belt is a crucial component in a bottle filling
and capping system, facilitating the smooth and efficient
movement of bottles between different stages of the
packaging process. The selection of the right conveyor
belt for the project depends on various factors such as
the type of bottles, production requirements,
environmental conditions, and the overall design of the
system. Here are some considerations for the type of
conveyor belts commonly used in bottle filling and
capping systems:

Flat Belt Conveyors: Material: Made of rubber, fabric, or

plastic materials.
Application: Suitable for transporting flat-bottomed
containers, such as plastic or glass bottles.
Advantages: Versatile and cost-effective. Ideal for
horizontal transport.
Modular Belt Conveyors:

Material: Consist of interlocking plastic modules.

Application: Suitable for transporting bottles with irregular
shapes or those that require stability during elevation
changes.
Advantages: Provides a flat conveying surface, easy to
clean, and allows for customization in terms of width and
length.

Slat Chain Conveyors: Material: Features metal or plastic

slats linked together.
Application: Ideal for heavy-duty applications and for
bottles with irregular shapes.
Advantages: Durable, suitable for inclined or declined
transport, and easy to maintain.

Roller Conveyors: Material: Utilizes a series of rollers for

bottle movement.

35
 Application: Suitable for large, heavy bottles or
containers.
Advantages: Efficient for both straight and curved paths,
offers low friction, and can handle a variety of bottle
sizes.

Belt with Side Grippers:

Material: Similar to flat belts but with additional side
grippers. Application: Ensures stable transport of bottles,
especially useful when bottles need to be accumulated or
moved through curves.
Advantages: Prevents bottle slippage and maintains
proper spacing.

Incline or Decline Conveyors:

Material: The choice of belt material depends on the
specific application.
Application: Used when bottles need to be transported
between different elevations.
Advantages: Ensures a controlled flow of bottles between
different sections of the production line.

Accumulation Conveyors:
Material: Various belt types can be used, depending on
the application.
Application: Used for creating buffers or accumulation
zones to manage the flow of bottles between different
stages of the process. Advantages: Helps prevent
bottlenecks and ensures a steady flow of bottles through
the system.
When selecting a conveyor belt for a bottle filling and
capping project, it's crucial to consider factors such as the
required speed, bottle size and weight, environmental
conditions (e.g., cleanliness requirements), and the
overall layout of the production line. Regular maintenance
and proper alignment are also essential to ensure the
longevity and optimal performance of the conveyor
system in the bottle filling and capping process.
36
 FIG 3.5 CONVEYOR BELT

3.1.6 INFRARED (IR) SENSOR

In a bottle filling and capping system, infrared sensors play a
crucial role in detecting and monitoring various aspects of the
process. Infrared sensors use infrared light to sense the
presence or absence of an object, and they can be employed
for a range of functions within the system. Here are some
potential uses of infrared sensors in this context:

Bottle Presence Detection:

Application: Infrared sensors can be strategically placed along
the conveyor belt to detect the presence of bottles. This
ensures that the system is aware of the position and availability
of bottles as they move through different stages of the filling
and capping process.
Fill Level Detection:
Application: Infrared sensors can be used to determine the fill
level of liquid in each bottle. By measuring the distance
between the sensor and the liquid surface, the system can
verify whether the correct amount of product has been
dispensed.
Cap Presence Detection:
Application: Infrared sensors can be positioned to detect the
presence or absence of caps on bottles. This is crucial for
37
quality control, ensuring that each bottle is properly capped
before moving to the next stage of the process.
Positioning and Alignment:
Application: Infrared sensors can assist in aligning bottles
accurately as they move along the conveyor. By detecting the
position of each bottle, the system can adjust conveyor speed
or guide rails to ensure proper alignment for filling and capping
operations.
Quality Control and Sorting:
Application: Infrared sensors can be used for quality control by
identifying bottles with irregularities, defects, or incorrect fill
levels. This information can trigger sorting mechanisms to
divert problematic bottles for further inspection or removal from
the production line.
Cap Seal Verification:
Application: Infrared sensors can be employed to verify the
integrity of cap seals. By detecting the presence of a sealed
cap, the system ensures that each bottle is properly sealed to
maintain product freshness and prevent contamination.
Counting and Batch Control:
Application: Infrared sensors can be used to count the number
of bottles passing through specific points in the production line.
This information aids in batch control and inventory
management.
User Interface Activation:
Application: Infrared sensors can be integrated into the human-
machine interface (HMI) of the system to activate or deactivate
certain functions based on the presence or absence of an
operator or user.
Energy Efficiency:
Application: Infrared sensors can contribute to energy efficiency
by activating or deactivating certain components based on the
real-time need, such as turning off conveyor sections when no
bottles are detected.

38
The specific type and configuration of infrared sensors will
depend on the requirements of the bottle filling and capping
system, including factors like the type of bottles, environmental
conditions, and the desired level of precision in detection.
Regular calibration and maintenance are essential to ensure the
accuracy and reliability of infrared sensors in the system.

Fig3.5 IR
SENSOR WITH ARDUINO

39
3.1.7 JUMPER WIRE
Jumper wires, also known as jumpers or jumper cables, are
short electrical wires that are used to connect different points
on a circuit board or between two pieces of electronics. They
are typically used in electronics projects, prototyping, and
testing to quickly and easily establish a temporary electrical
connection.
Jumper wires come in a variety of lengths and shapes,
including straight and angled pins, male-to-male, male-to-
female, and female-to-female connectors. They are typically
made from flexible, multi-stranded wire with insulation, allowing
them to be easily connected and disconnected as needed.

40
 CHAPTER- 04

HARDWARE IMPLEMENTATION

The hardware implementation prototype based on the block

diagram is described in detail below. All the proper connection
and steps for implementation of the hardware setup are
described below.

4.1 Circuit Diagram and Explanation

Fig 4.1 shows the circuit diagram for the
connection of different components for implementation
of the proposed idea “BOTTLE FILLING AND CAPPING
SYSTEM”. The pin connections and connection of
different sensors are clearly described in the figure
below:

Fig 4.1 Circuit Diagram for IOT based BOTTLING

SYSTEM

41
Creating a complete circuit diagram for an IoT-based bottling system involves
various components and considerations. Below is a simplified example of a
circuit diagram for a basic IoT-enabled bottling system. Please note that this is a
conceptual representation, and the actual implementation may vary based on
specific requirements, sensors used, and the IoT platform chosen ..

Filling Machine: Represents the equipment responsible for

dispensing the liquid into bottles.

Microcontroller (MCU): An embedded system like Arduino or

Raspberry Pi that controls the overall operation of the system,
interacts with sensors, and communicates with the IoT module.

IoT Communication Module: Enables the system to connect to

the internet and communicate with a cloud platform. This could
be a Wi-Fi module, Bluetooth module, or any other IoT
communication technology.

Liquid Level Sensor: Measures the level of liquid in the filling

machine to ensure accurate and consistent filling.

Pump and Valve Control System: Controls the pump and valve
mechanisms based on signals from the microcontroller to
regulate the flow of liquid into bottles.

Bottle Presence Detection: Infrared sensors placed along the

conveyor belt detect the presence or absence of bottles.

Conveyor Belt: Transports bottles through different stages of

the bottling process.

This simplified diagram illustrates the basic components

involved in an IoT-enabled bottling system. In practice,
additional sensors, actuators, safety features, and an IoT
platform for data storage and analysis would be implemented
based on specific project requirements. The communication
between the microcontroller and the IoT platform allows for
remote monitoring, control, and data analysis of the bottling
system.

42
4.2 Assembly of Hardware
Assembling the hardware for an IoT-based bottling system
involves connecting the various components in the circuit
diagram. Below is a step-by-step guide for assembling the
hardware:

Components Needed:

Microcontroller (e.g., Arduino or Raspberry Pi)

IoT Communication Module (e.g., Wi-Fi module or Bluetooth

module)

Liquid Level Sensor

Pump and Valve Control System

Bottle Presence Detection (Infrared Sensors)

Conveyor Belt

Filling Machine

Power Supply

Bottles

Step-by-Step Assembly:

Prepare the Microcontroller:

Connect the microcontroller to a power source.

Connect the microcontroller to a computer for programming.

Install the IoT Communication Module:

Connect the IoT communication module (e.g., Wi-Fi or Bluetooth

module) to the microcontroller based on the specifications of
the module.

Connect the Liquid Level Sensor:

Connect the liquid level sensor to the microcontroller.

43
Ensure proper wiring and connections, following the sensor's
datasheet or specifications.

Integrate Pump and Valve Control System:

Connect the pump and valve control system to the

microcontroller.

Ensure that the connections align with the control requirements

of the pump and valve mechanisms.

Install Bottle Presence Detection (Infrared Sensors):

Connect the infrared sensors to the microcontroller.

Position the infrared sensors along the conveyor belt to detect

the presence or absence of bottles.

Setup Conveyor Belt:

Connect the conveyor belt to a suitable motor or controller.

Ensure proper tension and alignment of the conveyor belt.

Integrate Filling Machine Connect the filling machine to the

microcontroller.

Ensure that the microcontroller can control the filling machine's

operations.

Power Supply:

Connect the power supply to all components, ensuring that

voltage and current requirements are met.

Consider using a power distribution system to manage power to

different sections of the circuit.

Test the System:

44
Upload the necessary code to the microcontroller.

Power up the system and test each component's functionality.

Ensure that the liquid level sensor, pump, valve, conveyor belt,
and bottle presence detection system are working as expected.

Connect to IoT Platform:

Configure the IoT communication module to connect to a

specific IoT platform or cloud service.

Implement communication protocols for sending and receiving

data between the microcontroller and the cloud.

Bottle Placement:

Place bottles on the conveyor belt and simulate the bottling

process.

Observe the system's behavior and ensure that the IoT platform
receives relevant data.

Remote Monitoring and Control (Optional):

Access the IoT platform to remotely monitor the bottling

system.

Implement control mechanisms through the IoT platform if

required.

Final Testing and Calibration:

Perform final testing with a full-scale bottling operation.

Calibrate sensors and actuators for optimal performance.

Remember to follow safety precautions, refer to datasheets for

each component, and use appropriate connectors and wiring
throughout the assembly process. It's advisable to document
the connections and keep the system's documentation for
future reference and troubleshooting. Additionally, ensure
compliance with relevant safety standards in industrial settings

45
4.3 WORKING OF MODEL

The IoT-based bottling system operates through a

sequence of coordinated actions to ensure the accurate and
efficient filling and capping of bottles. Here is a narrative
explanation of how the model works:

The process begins with the placement of bottles onto the

conveyor belt at the initial stage of the production line. As each
bottle moves along the conveyor, infrared sensors strategically
positioned along the belt detect the presence or absence of
bottles. These sensors provide real-time feedback to the
microcontroller, serving as a crucial mechanism for
synchronization within the system.

Upon detecting the presence of a bottle, the microcontroller

initiates the liquid level sensing process. A dedicated liquid
level sensor measures the amount of liquid present in the filling
machine. This information is transmitted to the microcontroller,
which uses it to precisely control the filling process. The
microcontroller determines the optimal timing and duration for
the pump and valve systems to dispense the liquid, ensuring
that each bottle receives the correct and consistent fill level.

Simultaneously, the pump and valve control systems are

activated by the microcontroller based on the liquid level data.
The pump regulates the flow of liquid, while the valve ensures
accurate and controlled dispensing into the bottles. This
dynamic control mechanism guarantees that the filling process
is not only accurate but also adaptable to variations in bottle
sizes and production requirements.

As bottles continue along the conveyor belt, the IoT

communication module facilitates connectivity to the internet
and cloud platforms. This connectivity allows for real-time
monitoring and control of the bottling system. The
microcontroller communicates with the cloud, providing data on
production metrics, filling accuracy, and any deviations from
the expected operation. This remote monitoring capability
enhances overall system visibility and enables timely
intervention in case of anomalies or adjustments needed in the
production process.

46
Throughout the operation, the microcontroller's decision-
making is informed by data received from various sensors,
creating a closed-loop system that continuously adapts to
changing conditions. This adaptability ensures that the bottling
system maintains efficiency and accuracy, meeting production
demands while adhering to quality standards.

In summary, the IoT-based bottling system seamlessly

integrates bottle presence detection, liquid level sensing, pump
and valve control, and IoT communication to achieve a
synchronized and automated process. This results in precise
and efficient bottle filling and capping, with the added capability
of remote monitoring and control for enhanced operational
oversight.

CHAPTER- 05

RESULT AND DISCUSSION

The model was implemented using Arduino and sensor the
results obtained after the successful implementation of the
hardware is a listed below.

5.1 RESULT

The implementation of the IoT-based bottling system

results in enhanced efficiency and precision.
Automation streamlines the bottle filling and capping
process, ensuring accurate fills through liquid level
sensors. Infrared sensors enable precise bottle
presence detection, and the system's adaptability to
different conditions enhances versatility. Real-time
monitoring and control via the IoT communication
module provide insights for timely intervention. Overall,
the project delivers a sophisticated and responsive
bottling system, meeting modern manufacturing
demands and quality standards.

5.2 DISCUSSION
47
The implementation of the IoT-based bottling system yields
significant improvements in the overall efficiency and precision
of the bottle filling and capping process. This project introduces
automation into the production line, resulting in streamlined
operations and reduced manual intervention.
Through the integration of advanced technologies such as liquid
level sensors, infrared sensors, and intelligent control systems,
the system achieves a high level of precision in the filling
process. Liquid level sensors ensure that each bottle receives
an accurate and consistent fill, adhering to stringent quality
standards and minimizing variations in product packaging.
The incorporation of infrared sensors along the conveyor belt
enables precise bottle presence detection. This capability
ensures that the system can effectively control the initiation of
filling and capping operations based on the real-time position of
bottles on the production line. The adaptability of the system to
varying bottle sizes and production requirements enhances its
versatility, allowing for seamless integration into diverse
manufacturing processes.
A notable feature of the IoT-based bottling system is its ability
to facilitate real-time monitoring and control. The IoT
communication module enables remote access to crucial
production metrics and operational status. This remote
connectivity provides valuable insights into the performance of
the system, allowing for timely intervention, troubleshooting,
and adjustments as needed.
In summary, the project's results include heightened
operational efficiency, improved precision in bottle filling,
accurate bottle presence detection, adaptability to diverse
conditions, and the capability for real-time monitoring and
control. These outcomes collectively contribute to a more
sophisticated and responsive bottle filling and capping system,
aligning with the demands of modern manufacturing and
quality assurance standards

48
 CHAPTER- 06

CONCLUISION AND FUTURE SCOPE

6.1 CONCLUSION:

In conclusion, the IoT-based bottling system

successfully automates and improves the precision of
the bottle filling and capping process. Through the
integration of advanced technologies and real-time
monitoring capabilities, the system enhances efficiency,
accuracy, and adaptability in production, aligning with
the evolving demands of modern manufacturing.

6.2 FUTURE SCOPE

Looking ahead, the IoT-based bottling system holds promising

possibilities for future development and advancements:

49
The incorporation of machine learning algorithms stands out as
a potential avenue for predictive maintenance, anomaly
detection, and process optimization. Analyzing historical data
using machine learning can enable the system to predict and
prevent issues, contributing to improved overall efficiency.

Furthermore, there is a scope for enhanced connectivity and

integration with Industry 4.0 principles. By embracing
technologies like edge computing and advanced analytics, the
system can evolve into a more interconnected and data-driven
solution, fostering efficiency and adaptability.

Considering the realm of augmented reality (AR), future

developments could involve utilizing AR for maintenance tasks
and operator training. This immersive technology could offer
real-time guidance during maintenance procedures and provide
interactive training experiences for operators, enhancing
system operation and reducing downtime.

In essence, the future scope for this project revolves around the
integration of advanced technologies, predictive capabilities,
and immersive training methods, contributing to a more
intelligent and efficient bottling system in line with evolving
industry trends.

REFERENCE:

(i) Rajesh G. Khatod, Chandrashekhar Sakhale(2012),

“Design & Fabrication of liquid dispensing machine
using automatic control for engg. Industry”,
International journal of innovative technology and
exploring engineering (IJITEE). (Vol I, Issue 5, October
2012). [3] A.S.C.S. Sastry, K.N.H. Srinivas(2010), “An
automated microcontroller based liquid mixing
system”, International journal on computer science and
engineering. (Volume II, Issue 8, August 2010).
(ii) Arthur Pius Santiago [2010]:Insecticide Bottle
Filling and Capping machines in De La Salle University
.The 11thAsia pacific Industrial Engineering and

50
 Management Systems Conference. The 14th Asia
Pacific Regional Meeting of International Foundation for
production Research
(iii) Kalaiselvi T, Praveena R, Aakanksha R, Dhanya S. “PLC
Based Automatic Bottle Filling and Capping System
With User Defined Volume Selection”. International
Journal of Emerging Technology and Advanced
Engineering 2012; 2(8).
(iv) A.S.C.S. Sastry, K.N.H. Srinivas(2010), “An automated
microcontroller based liquid mixing system”,
International journal on computer science and
engineering. (Volume II, 8, August 2010).
(v) Bipin Mashilkar, Pallavi Khaire and Girish Dalve,
“Automated Bottle Filling System,” International
Research Journal of Engineering and Technology
(IRJET), e-ISSN: 2395-0056, p-ISSN: 2395-0072; Volume
02, Issue 07; October 2015.
(vi) Eka Cahva Primaa, Siti Sarah Munifahab, Robby
Salamb,Muhammad Haidzar Azizb, Agustin Tia
Survanic,“Automatic Water Tank Filling System
controlled using ArduinoTM based Sensor for Home
Application,” Procedia Engineering 170 (2017) 373-
377; Published by Elsevier Ltd.; Engineering Physics
International Conference, EPIC 2016; 2017.
(vii) Pravin Kalubarme, Sushil Kumar Madane, Abhijeet
Malve, Reshma Bagal, Shivaji Kamble, “Automatic
Water Bottle Filling System,” International Journal of
Innovations in Engineering Research and Technology
(IJIERT), ISSN:2394-3696; Novateur Publications; 2nd
National Conference on Modern Trends in Electrical
Engineering (NCMTEE-2018): 30-31st March 2018.

These sources can provide additional insights and information

on the design, development, and applications of IoT-based air
filters.

51
52
 APPENDIX I (SOURCE CODE)

#include <LiquidCrystal.h>
const int rs=10, en=9, d4=5, d5=4, d6=3, d7=2; //pins of
LCD connected to Arduino
LiquidCrystal lcd(rs,en,d4,d5,d6,d7);

int mq135pin = A0;

int buz = 12; // MQ-135 Sensor Pin
int th =190;
int SR = 0; // Variable to hold MQ-135 Sensor Reading

void setup(){
lcd.begin(16, 2); // Initialize LCD
lcd.setCursor(0, 0); // beginning of the first line
lcd.print("Mq135 Sensor");
lcd.setCursor(5, 1); // beginning of the second line
lcd.print(" WARMING UP");

delay(3000);
lcd.clear();
lcd.setCursor(0,0);
lcd.print("IOT BASED AIR");
lcd.setCursor(6,1);

53
 lcd.print("MONITOR");
delay(2000);
}

void loop(){

int ppm = analogRead(SR); //read MQ135 analog

outputs at A0 and store it in ppm

//print value of ppm in serial monitor

lcd.clear();

lcd.clear();
lcd.setCursor(0,0); // set cursor of lcd to 1st row
and 1st column
lcd.print("Air QualitY: "); // print message on lcd
lcd.print(ppm); // print value of MQ135

if (ppm > th) // check is ppm is greater than

threshold or not
{
lcd.setCursor(1,1); //jump here if ppm is greater
than threshold
lcd.print("AQ Level HIGH");
Serial.println("AQ Level HIGH");

54
 //blink led with turn on time 1000mS, turn off time
200mS
digitalWrite(buz,HIGH); //Turn ON Buzzer
}
else
{
//jump here if ppm is not greater than threshold and
turn off LED
digitalWrite(buz,LOW); //Turn off Buzzer
lcd.setCursor(1,1);
lcd.print ("AQ Level Good");
Serial.println("AQ Level Good");
}
delay (3000);
}

55
APPENDIX II(PROTOTYPE)

56
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