Bottles Filling Line Automation

Coca-Cola Company is the world's largest NECESSITATE:

Initially regular bottles filling line was manual. There
S T O R Y

beverage company established in 1886, refreshing

are twelve conveyors as a whole which were derived by

consumers with nearly 500 sparkling and still brands.
Along with Coca-Cola®, recognized as the world's
most valuable brand, the Company's portfolio
includes 12 other billion dollar brands, including Diet
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VFD's. They used potentio meters to adjust the speed of
each conveyor. They have to adjust speed of each
conveyor time by time in order to increase through put

Coke®, Fanta®, Sprite®, Coca-Cola Zero™ and Kinley
Pure Drinking water. Globally, they are the No. 1
provider of sparkling beverages, juices and juice
drinks and ready-to-drink teas and coffees. Through
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of line. All the conveyors are continuously running until
or unless operator stops them one by one. The following
things they need.

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the world's largest beverage distribution system, ¬ They required a system that automatically
consumers in more than 200 countries enjoy the adjusts the speed of conveyors.
Company's beverages at a rate of 1.6 billion servings ¬ Interlock between all the conveyors to reduce the
a day. power consumption.
¬

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They own four of the world's top five nonalcoholic Data logging for years i.e. bottles per day or
sparkling beverage brands: Coca-Cola, Diet Coke, bottles per shift, per month.
Sprite and Fanta. 92,800 employees are associated ¬ Alarming.
¬ To increase the through put and production of
with the company worldwide.
line by reducing down time.
S U C C E S S

PROBLEMS FACING BY COCA COLA: ¬ Engineering work station to view the whole
process in control room.

¬ There are twelve conveyors as a whole
which were derived by VFD's. All conveyors
follow the filler speed i.e. if operator increases
the filler speed then he has to adjust speeds of
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Mr. Imtiaz from Production department and his team
took the initiative to resolve the issue. They require high
performance, low cost, and reliable system for their

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each conveyor (12 conveyors) manually application.
according to the filler, this ultimately reduce
the production.
¬ All Conveyors were continuously running all
the time weather the filler is running or not!
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That leads to the power loss, and in order to
stop them operator has to stop each conveyor
one by one.
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¬ No interlocking of conveyors which cause the

threat of breaking bottles.
¬ No history of any problem in lines.
¬ No counter and rate of bottles

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 Bottles Filling Line Automation
SOLUTION: Now the Bottle Filling Line is fully automated. Every
As the name goes “Solutions conveyor adjusts its speed according to the bottle filler
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Engineering (Pvt.) Ltd.” (SEPL), With its global automatically. If bottle filler stop then all the conveyors

partner GE-IP has provided the solution that not only
meet the exact requirements of the client but also
have the latest technology and better support that
comprehend Coca Cola Pvt. Ltd to give us this
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stops accordingly depending upon certain conditions,
that cause considerable reduction in power
consumption.
We also provides bottle counter which count total

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opportunity to solve the problem on there critical production of the line and save files in SD card in CSV
application. format
Bottle Filler in the line acts as master device because PLC PANEL

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each conveyor has to run according to the filler speed,
if filler stops then conveyors should stop if it starts
then conveyors should start .if the Bottle Filler speed
increases then the conveyors speed should increase
accordingly and vice versa.

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SEPL had installed the GE-IP PLC along with sensors
on each conveyor to detect the presence of bottles.
These sensors give indication to PLC system. Speed,
start, stop, and trip indication of Bottle Filler also
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goes to the PLC system. The speeds of all the

conveyors are controlled by VFD's through GE-IP PLC

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system.
Bottle Filling Line Overview
Motor

VFD PANEL
Motor

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Sensor
Motor
Motor

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Checking

Sensor
Filler

Washer
Capper

Packing &
Sensor
Handling
Checking

Sensor
Motor
Counter/ Rate
Calculator

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 Bottles Filling Line Automation
We use GE-IP Versa Max PLC with Red lion HMI and an engineering work station. System configuration
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is given blew.
Versamax PLC HMI G308

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Ethernet Switch

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Ethernet Link Ethernet Link

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Contol room Engineering Ethernet
work station Link
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BENEFITS:

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For such kind of process we provide low cost, highest performance solution.
¬ System provides the facility to auto adjust the speed of conveyors according to the bottles filling rate.
¬ If no bottles on line the conveyors will stop automatically and vise versa.
¬ Less energy consumption. O
¬ Emergency stop line facility in case of any emergency.
¬ Data logging.
¬ Alarming.
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¬ System can be extended in order to meet the future requirements.

¬ System is fully reliable.
¬ It has reduced the down time to minimum level.
¬ More enhanced Diagnostic features.
¬ User friendly, Easy maintenance.

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 Bottles Filling Line Automation
PANELS OVERVIEW
S T O R Y

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S U C C E S S

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