ADIGRAT UNIVERSITY

COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OFELECTRICAL& COMPUTER ENGINEERING
STREAM INDUSTRIAL CONTROL
DIMMA HONEY PROCESS PLC (HOISTING COMPANY)

DESIGN PROJECT:PLC BASED AUTOMATIC BOTTLES FILLING AND CAPPING SYSTEMS

PREPARE

SYOUM HAILE 4199/07

Duration of Time: 29/07/2010 – 29/10/2010E.C

Submission Date: 26/02/2011E.C

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Declaration (Endorsement)

This is provide by me, I am a 5th year student of Adigrat University College of engineering and
technology department of electrical & computer engineering, have been working as an intern-
ship in Adigratdimma honey process p.l.c, Planning and industrial control stream from December
– February, 2011e.c as required in the curriculum. And have prepared this report from what I
have observed and practiced during my stay. These reports have been written by me and have not
received any previous academic credit at this or any other institution.

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Acknowledgment
First and foremost, iwould like to acknowledge God who is just so amazing, and thank Him
above all for helping me and being with me throughout my end ever. i would like to extend my
sincere gratitude to Adigrat University, University-Industry linkage and the dimma honey
processingp.l.c. for giving my this rare opportunity to be part of the company and experience
firsthand the work done in this prestige institution. i would also like to thank the workers in
dimma honey processingp.l.c. For being cooperative and welcoming. They have been very
helpful and willing to share their knowledge in their field of work. And i would like to thank our
mentor and instructor at Adigrat University, for the guidance and follow me. i would also like
to thank in particular MRO manager mister ALEM and leader Maintenance workshop. I
have come to learn a lot from these employees and they have taught me a lot without hesitation.
This has been a once in a life time experience for me and i would like to thank everyone who
made this internship possible for me.

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Executive Summery
This paper is a comprehensive internship report and project design on internship practice in the
2011 E.C academic year. It was prepared as one of the compulsory inputs for the proper
execution of the program.

This paper introduces part that incorporates background of the hosting company under which
are brief history of past & ongoing projects mission ,company supplier , company customer,
future plan ,main service , companies problem ,vision ,goal ,fully dedicated to our
overall internship experience , overall organization and workflow and overall benefits. I am
gained from the internship which are subcategorized into merits related to my professional
career, communication skills, interactions, work ethics and entrepreneurial skills. This starts with
describing my working section. Specific workflow along with undertaken tasks & involved
procedures are all under this section.Dimma honey process p.l.c.only work on the filtration of
honey & making candle.butsome times also makes tejj.

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Contents
Acknowledgment........................................................................................................................................iii
Executive Summery....................................................................................................................................iv
CHAPTER-ONE.........................................................................................................................................1
INTRODUCTION TO INTERNSHIP HOSTING COMPANY..................................................................1
1.1Background of dimma honey processing Plc......................................................................................1
1.3 Company inPutOutPut.......................................................................................................................2
1.3 Product Motto....................................................................................................................................3
1.4 Value of the Company.......................................................................................................................4
1.5 VissionOf The Company....................................................................................................................4
1.6 Objective of the Company.................................................................................................................4
1.7 Mission of the Company....................................................................................................................5
1.8 Company Supply of the Plant............................................................................................................5
1.9 Main Customer of the Plant...............................................................................................................5
1.10 Company Main Problem..................................................................................................................5
1.11 Future Expansion of the company....................................................................................................6
1.12 Organization Structure of Dimma Honey Processing Plc................................................................7
G/manager..............................................................................................................................................7
CHAPTER TWO.........................................................................................................................................8
Over All Internship Experience...................................................................................................................8
2.1 How We Get To The Company..........................................................................................................8
2.2 The section we have been working on...............................................................................................8
2.3 Work Flow of Dimma Honey Processing Plc...................................................................................8
2.3.1 Solid Honey Filtration Process.....................................................................................................8
2.4 The Industry of liquid Honey...........................................................................................................10
2.4.1 Description of Processing Steps................................................................................................10
2.5 Main duties of the processing room.................................................................................................13
2.6 Work responsibilities and Assignments............................................................................................14
2.7 Challenges I have been faced in the hosting company.....................................................................14
2.8 Measure I have taken in order to overcome the challenges..............................................................14

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CHAPTER-3.............................................................................................................................................16
PLC BASED AUTOMATIC BOTTLES FILLING AND CAPPING SYSTEMS.....................................16
3.1 Abstract............................................................................................................................................16
3.2 Introduction.....................................................................................................................................16
3.2.1 Automation...............................................................................................................................17
3.2.2 Plc.............................................................................................................................................17
3.3 Problem Of The Statement...............................................................................................................19
3.4 Project Objective.............................................................................................................................19
3.4.1General Objective......................................................................................................................19
3.4.2Specific Objective.......................................................................................................................19
3.5 Literature Review............................................................................................................................20
3.5.1 History Of Bottle Filling And Capping System Based On Plc......................................................20
3.5.2 History Of Plc............................................................................................................................20
3.6 Methodology...................................................................................................................................23
3.6.1 Project Over View.....................................................................................................................24
3.7System Model (Block Diagram........................................................................................................26
3.9 Process Description.........................................................................................................................28
3.9.1 Hardware Part:..........................................................................................................................28
3.10 How System Works.......................................................................................................................28
3.10.1 Bottle Detection Using Sensor.................................................................................................28
3.10.2 Filling Operation......................................................................................................................29
3.10.3 User Defined Wight.................................................................................................................29
3.10.4 Capping Operation..................................................................................................................29
3.11 Input And Output Assignment........................................................................................................30
3.11.1 Input Assignment....................................................................................................................30
3.11.2 Output Assignment.................................................................................................................31
3.12 Result And Discussion...................................................................................................................32
3.13 The Overall System Ladder Diagram.............................................................................................36
OVERALL BENEFITS GAINED FROM THE INTERNSHIP PROGRAM............................................38
4.1 Upgrading Theoretical Knowledge..................................................................................................38
4.2 ImprovingInterpersonal Communication.........................................................................................38
4.3 Improving Team Playing Skills........................................................................................................38

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 4.4 Improving Leadership Skill.............................................................................................................39
4.5 UnderstandingWork Ethics..............................................................................................................39
4.6 ImprovingEntrepreneurship Skills...................................................................................................39
CHAPTER -FIVE......................................................................................................................................40
Conclusion and Recommendation.............................................................................................................40
5.1 Conclusion.......................................................................................................................................40
5.2 Recommendation.............................................................................................................................40
REFERENCES..........................................................................................................................................41

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Figure Page no

Figure 1. 1 Type of Micro Filter with Service Jack...................................................................................10

Figure 1. 2 Raw honey batch with their color/type...................................................................................11
Figure 1. 3 Filtered honey and candle........................................................................................................12
Figure 1. 4 Company of Motto..................................................................................................................12
Figure 1. 5 Over all organization structure of the company.......................................................................16

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 CHAPTER-ONE

INTRODUCTION TO INTERNSHIP HOSTING COMPANY

1.1Background of dimma honey processing Plc
Dimma beekeeping development and honey processing p.l.c was established in January 2005 to
perform transformation production as well as marketing of bee products. The company’s
processing plant is located in Adigrat, 120km away from mekelle .The installed processing line is
years old and is based on technology from INDIA. The production capacity of this plant is 1440
tons per year. Total investment of the company is 16,000,000.Due to the presence of the
company; several job opportunities were and would be created for high, mid and low levels
personal. At present there are 31 employees having different qualification on permanent base of
employment and other new personal would be expected to be employed as the plant is working
in full capacity. Since the formation of the company it has been engaged in many actions mainly
on;Establishment of bee farms for honey and queen rearingProduction and honey
collection.Establishment of high tech processing machinery and processing.Because honey by its
nature it attracts dust and impurities contains disease caused anti biotic, so for that reason is
filtration is aveliable. The pollen and other having less density un wanted things are filtered by
separation process by the help of boiler temperature and some denser particle are putted at the
bottom of the unloading tank so it can filtered by using of different micro size, such as (100 -40)
× 10-6mm.
Figure 1.1 Type of Micro Filter with Service Jack

1.2 Location of address

The company is establishment at Adigrat town 898km & 120km far from Addis Ababa &mekelle
respectively, with in the specific industrial zone. It is 2.8km from the center of the town on the
way to mekelle. The specific land given by the concerned body is situated 40mts to the east from
the main road having good soil texture for construction, enough municipal water, electric power
and, telephone and transportation accesses.

1.3 Company inPutOutPut

The following are company inputs contained wax, soil, dust ,impurities such as pollen and die
honey as well as anti-biotic( bacteria and other organism that affect human health) bring from all
region of the country:since on the stroge room the honey is placed based on their type which are;

 Traditional honey (white and yellow)

 Modern honey (white, yellow and dim white).

Here these are raw material of the company steed with in there batch on the storage.

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Figure 1.2 Raw honey batch with their color/type

The output of the company is filtered these above raw honey called extra white,yellow,dim white
honey and tejj, as well as canddel as shown here…

Figure 1.3 Filtered honey and candle

1.3 Product Motto

Dimma beekeeping and honey processing plc, symbolize the natural honey produced by honey
bees and hopefully they would be daily dish mate of the customer.

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Figure 1.4 Company of Motto

1.4 Value of the Company

The value of this company is;
 Transparency.
 Socially responsible.

Work hard like bee & intensified by quality improvement

Customer oriented.

1.5 VissionOf The Company

To be proficient and leading producer and supplier of quality organic processed honey in to the
national as well as international markets.

1.6 Objective of the Company

The main aim of this company is:

 To produce high quality processed honey and wax and absorb (3-5) % of the national
domestic market (demand for honey and beeswax).
 Make ready organic pure honeys & wax for foreign market.
 Certifying by is 9001:2000 quality management system and HACCP principle and
make a preparation for organic certification.
 Maximizing profit from the high potential of apicultural output.
 Creating marketing network for honey & bees wax.
 Creation of out growers & provision beekeeping materials and training for having
traceable and sustainable suppliers.

1.7 Mission of the Company

The mission of this company is:

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  To contribute in sustainable change in commercialized apicultural
development of the region by transforming the existing way of practice sand
potentials through modern technology & management.
 To utilize the available natural resources in the region for better & diversified
advantage and maximization.
 To create job opportunity in places where the various activities are in
operation.

1.8 Company Supply of the Plant

The company supplies are the following;

 Different type of filtered honey, such as filter super white honey, super red honey,Tejj and
Candle

1.9 Main Customer of the Plant

The main customer of this company is;

 Import with in a different state in our country and

 Export to a different country, such as china, India,yemen...etc

1.10 Company Main Problem

The company has the following problems;
 The bottle capping and filling is done manually.
 The company has not lifted.During operation thehoneyshacked& carried by persons.
 The company has not full of tools which are important for the maintenance.
 The machine or all the tanks are not operates and no have sufficient liquid honey to be
supplied to the customer and huge fuel leads to fuel consummation & decrease boiler
efficiency.
 It is difficult to shake a honey during filtration and filling to the unloading tank (manually
shake).
 The Compressor is controlled manually.
 Boiler cooler is not function able (when the boiler suddenly super-heated it may be
burned and a company leads to vanish).

1.11 Future Expansion of the company

It will need to expand or to build;

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 Powder factory around here, and in Mekelle(dimma powder factory)
 Another similar honey process company in a different region of the country.

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 1.12 Organization Structure of Dimma Honey Processing Plc
G/manager

Secretary

Quarry& geology Department

Human &resource Department
Finance Department Maintenance Department
Supply Department Marketing Departme
Production Department

Maintenance Department head

Elector mechanical division head Garage Department head Quarry Department

Figure 1.5 Over all organization structure of the company

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 CHAPTER TWO

Over All Internship Experience

2.1 How We Get To The Company
First my head department requested me to fill the format of internship Host Company that I am
interested. my department faxed my letter then, after they have faxed back the acceptance paper.
When i reach at company i have had a letter which is given to me by my department, then they
accepted it. After one day they give me an orientation about the company how to use the
company access such us service, working time, department and other materials.

2.2 The section we have been working on

I have been working specially from the other departments in the processing room because this
section is highly related with my field of study and it have sensors that I have been learned that
before that’s why iwere passed my time in this section and also i interrelates the theoretical that i
learned before with practical one in this section. i have strongly developed my capacity to
improve in terms of practical skill, upgrading or applying the theoretical knowledge practically.
Sometimes when there is nothing to be done i see the boiler room and it’s manual and i see the
other sections.

2.3 Work Flow of Dimma Honey Processing Plc

Dimma honey process p.l.c the honey filtration process occurring on two physical phase; solid
and liquid honey, but usually the company processed on the solid honey, because a liquid honey
have the following problem such as;

 Demand
 Supply and it is simply crystallized after finishing product. And its amount dropped
through all tank but there is highly qualified than solid honey processed.

2.3.1 Solid Honey Filtration Process

A solid honey is used as in put to the filtration process. This is contains a wax, denser and less
denser un wanted particle such as dust and impurities,anti-biotic such as bacteria so on……

Because, honey by its nature it attract those like things so for that reasons honey filtration is
available.From a storage room solid honey is coming to the process room according to
theirbatch. The honey is shake manually as shown below after that drawn in to the jacketed
unloading tank carried up to 800KG of honey, since it is jacketed the unloading tank a hot water

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is enter to it from a steam boiler. The honey and hot water are not mix together in the unloading
tank, since it is jacketed.

It is only heat is transfer by conduction system due to the temperature variation and shake by the
help of agitators. The agitators coupled to the dynamo or motor pump shaft they rotate together
remix a honey to be floated the un wanted thing at the top and bottom of the honey at that
temperature. The hot water coming from boiler is adjusted at 870c and is enter to the unloading
tank to heat the cold honey up to 600c.so when it reaches at that temperature un wanted things in
the honey floats on the top(less denser) such as, pollens.Bee die, and sink at the bottom (denser
particle) such as, dust, soileds.Those less density un wanted thing are simply removed by the
process of separation and denser particles are removed by filtration methods. We have two kind
of filtration process those are as follow;

 100mm Micro filtration process and,

 40mm micro filtration process.
100mm Micro filtration process;
 It flits a dust or soil having 100 × 10-6mm in size, but some a small particle are passed
so it need another filter less in size such as 40mm micro filter.
40mm micro filtration process;
 It flits a small particle those cannotfelt by100mm micro filter (dust or soil)having 40 ×
106mm in size. After the honey pass through those filtration put in to natural
fiber.Thehoney from unloading tank pass or transfer to the micro filters by the help of
transfer pumps one (pt1), as shown below.

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Figure 2.1Transfer Motor Pump 1 & Unloading Tank

After three days also the filtered honey drawn in to the in to the settling tank for settling process
for eight days, shakes by agitators for the help of removing foam, and bubbles.After that the
filtered honey can be packed. Generally, a solid honey is processed on the unloading tank, and
filter regarding to the function of boiler and pump transfer one.

2.4 The Industry of liquid Honey

2.4.1 Description of Processing Steps

The industry of honeys is not a simple sequential chain of processing operations, although the
normal consumer may consider it in this way, at first sight. It should be noted that each
processing step, from the initial harvest to the packaging of the final food product, is the answer
to peculiar problems concerning the physicochemical and biological features of different honeys.
This topic is dedicated to the description of liquid honey production. In general, the

following integrated steps correspond to the flow-chart description of such a process.

Raw Liquid honey → Unloading tank → filtertank → balance tank → pasturizer tank
→ evaporater → dearator → cooler → settlingtank → finalpackaging .

2.4.1.1Unloading Tank
The most production process of the company is finished at this tank as defined in the
above. since this tank is jacketed it contains a hot water during the operation to transfer a
heat in to a cold honey by conduction system for the purpose of easily filtration process.
This tank has in let( where, hot water from a boiler is enter) and out let(for the purpose of
revers a hot water in to water tank) valve by fluid mechanics action and motor pump is
coupled with the agitators at the top as shown in the figure bellow;

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Figure 2.2 Unloading Tank
2.4.1.2Filter Tank
Filter tank as its name indicates it uses for filtration process, contain a macro filter in side
for the purpose of removing denser particle, such as soil, and dust presents in the honey
that are not floats on the top of the unloading tank by passing through a pipe by the help
of transfer pump one. Its flow of the liquid honey controls by the check valve. This filter
tank is positioned vertically and it can move easily, since it have a service jack at the
bottom shoes as shown.

Figure 2.3 Filter Tank

2.4.1.3 Balance Tank
The balance tank is an intermediate element or equipment positioned vertically between the filter
tank and pasteurizer tank as shown below, its main function is to control the over flow of the
honey, and to hold a pumped honey from the unloading tank transferred by the help of transfer
pump 1.

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Figure 2.4 Balance Tank
2.4.1.4 Pasteurizer Tank
A pasteurizertankit is a jacketed tank (surrounded by hot water coming from boiler) its main
purpose is;

 To increase honey safety for the consumer by destroying disease causing microorganisms
that may be present in honey.
 To increase keeping the quality of honey products by destroying spoilage microorganism
and enzymes that contribute to the reduced quality and shelf life of honey.

2.4.1.5CoolerTankand Evaporate Tank

As we know cooler is a device used to condensed a substance from its gaseous to its liquid state,
so in case of this plant its Main function is to condensed a honey to decrease it crystallize

2.4.1.6 DearatorTank
A deaerator is a device that is widely used for the removal of oxygen and other dissolved gases
from the feed water to steam-generating boilers. In particular, dissolved oxygen in boiler feed
water will cause serious corrosion damage in steam systems by attaching to the walls of metal
piping and other metallic equipment and forming oxides (rust). Dissolved carbon dioxide
combines with water to form carbonic acid that causes further corrosion. Most deaerators are
designed to remove oxygen.

2.4.1.7 SettlingTank
Final Packaging Is built with mechanical means for continuous removal of solids being deposited
bysedimentation (it is a process of removal accumulated solid particle).

Settling tank is generally used to remove solid particulates or suspended solid from liquid for
clarification.Concentratedimpurities, discharge from the bottom of the tank are known as sludge,

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while the particles that float to the surface of the liquid are called scum. Here itsWith reference to
the final packing, small quantities of honey can be easily packaged placing the vat and decant
honey at least 50 cm from the ground. The vat must be equipped with a large cutting tap or ball
which will be placed under the vessel to be filled. The vessel must be placed under a calibrated
balance (the weight of the empty vessel has to be considered ‘zero’) to control labelled net
weight. For medium or large amounts of honey, automatic dosing pumps, adjustable from 25 to
1000 g, can be used: the complete packaging step becomes easier andfaster. Higher quantities
would require further machines able to withdraw, fill and seal the bottles automatically.

2.4.1.8 Final Packaging

With reference to the final packing, small quantities of honey can be easily packaged placing the
vat and decant honey at least 50 cm from the ground. The vat must be equipped with a large
cutting tap or ball which will be placed under the vessel to be filled. The vessel must be placed
under a calibrated balance (the weight of the empty vessel has to be considered ‘zero’) to control
labelled net weight. For medium or large amounts of honey, automatic dosing pumps, adjustable
from 500 to 1000 g, can be used: the complete packaging step becomes easier and

faster. Higher quantities would require further machines able to withdraw, fill and seal the bottles
automatically.

2.5 Main duties of the processing room

The main duties of this processing department is ;

 On motors, sensors

 Works properly stop, start, regulate.

 Control properly communication transmission of data is checked& operate fluently.

 Work in proper time with safety manner.

 The signal for the whole controllable system in processing is transferred with adjusting
time by manually.

And also;

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  Perform final finishing and controlling the out puts

 Ensure that all materials issued are correct for the product
 Ensure that finished honey consist of high quality standard and that measurements with in
tolerance laid down in the customer satisfaction etc.

2.6 Work responsibilities and Assignments

During my forth month internship program the main assignments are to identifying the company
problem ,finding solution as we are engineer and also understand the overall company process,
as well as my responsibility is to obey the rule and regulation of the company.

2.7 Challenges I have been faced in the hosting company

In this world people facing a lot of challenges to live and to get something and i facing
challenges it may be very difficult or it may be easy to facing. Just i think facing of any
challenges during work progress is one part of the objective of the internship, so while i
performing my task with some challenges that invite me to challenging them, such as ; in dimma
honey processing company there is only one electrical engineers, rather they are chemists,
industrial chemistry’s and the operators are doing through experience. So they did not have full
knowledge about the machines unit operations as well as they don’t know the specific sensor that
the machine used, and also there is no enough accesses such internet service and good manuals.
Again there is no transportation service Just I have tried to facing because the company is far
from the university.
Generally the most thing that i get challenge in dimma honey processing plc is; Site language- when i
joined in to the company the name of processing material made me confusion.

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2.8 Measure I have taken in order to overcome the challenges
As i mentioned the challenges above, i were faced with a lot of challenges; i had look
alternatives to solve them. To solve these problems or challenges i have taken the following
measures.
Regarding to site language i decide to create a good relationship with the daily workers of the
department. All things are simple to know on process after a time, to know the work task of each
employees i decided to arrange a program that meets with the employee for each then the
problem was solved and they are volunteer (responsible) to accept my program, the challenges
regarding to experience as explained above i have good friend ship with all the workers or
employees, so them helps to build a confidence and to communicate with us freely, at that time i
get a good experience from the employee and from the skilled persons.and also i read some
manuals of each section to know the flow and working principles of the machines.Generally
most of the challenges were solved through my effort after hard working.

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 CHAPTER-3

PLC BASED AUTOMATIC BOTTLES FILLING AND CAPPING

SYSTEMS
3.1 Abstract
Filling and Capping system of the Bottle automatically become easiest one and time saving
process with the help of Machines. The honey filled to the Bottles can be containing different
weight which the operator could be defined. The aim of this project on automatic Bottle filling
and capping system using Programmable Logic Controllers (PLC‟s) is to simultaneously filling
the honey to the bottles and the same time capping the bottles. This process, compared with the
old traditional process of filling bottles is the time saving and most efficiency. The system
sequence of operation is designed by ladder diagram of PLC programming software. Sensor is
very important for detecting the positioning of the bottles, and Conveyer Belt is for taking the
bottles from one place to other specifying it work.

3.2 Introduction
Control engineering has evolved overtime. In the past, humans were the main method for
controlling a system. More recently, electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relay to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable

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Logic Controller (PLC). The advent of the PLC began in the 1970‟s, and has become the most
common choice for manufacturing controls.

In our worldwide through technology many things become easy with the use of machineries. But
the use of machines need great care for their operation and their function needs very great
knowledge to apply.

As with the title that “PLC based automatic bottle filling and capping system”. It is a system
which consist many process together and these are:

 PLC
 Automation
 Bottle filling and
 Bottle capping

3.2.1 Automation

Automation is defined as the use of information technology to increase the efficiency of any
product, reducing the hard work of human being which had been time consuming and in
efficiency. Automation plays great role in the industrialization process. Decreasing the human
mental involvement on the work.And in the world economy and daily experience, automation.

3.2.2 Plc

PLC has been gaining popularity on the factory floor and will probably remain predominant for
some time to come. Most of this because of the advantages:-

 Cost effective for controlling complex systems

 Flexible and can be reapplied to control other systems quickly and easily
 Computational abilities allow more sophisticated control
 Trouble shooting aids make programming easier and reduce downtime.
 Reliable components make these likely to operate for years before failure.
Control systems are an integral part of modern society. It consists of subsystems and
processes assembled for the purpose of controlling the outputs of the processes. There are
many numerous applications that using control system around us. A control system
provides an output or response for a given input or stimulus. The reason that control
system was built is for power amplification, remote control, convenience of input form;
and compensation for disturbances. Today control systems find widespread application in
the guidance, navigation, and control of missiles and spacecrafts, as well as planes and
ship at sea. The applications also throughout the process control industry, regulating
liquid level tanks, chemical concentrations in vats, as well as thickness of fabricated
material.

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  Open Loop System
It starts with sub system called an input transducer, which converts for the input to that used by
the controller. The controller devices a process or plant. Then input sometimes called reference,
while the output can be called the control variable. Other signals, such as disturbances are shown
added the controller & process outputs via summing junctions, which yields the algebraic sum of
their input signals using associated sign.

Figure 3.1 open loop system

The distinction characteristics of an open loop system is that it cannot compensate for any
disturbances that added to the controller’s driving signals. The output of an open loop system
computed not only by the signals that add to the controller’s commands but also the disturbances
at the output. The system cannot correct for these disturbances & are simply commanded by the
input.

 Closed Loop System

The disadvantage of open loop system, namely sensitivity to disturbances an inability to correct
these disturbances, may be over ten in closed loop systems. The input transducer converts the
form of the input to the form used by the controller. An output to the transducer, or sensor,
measures the output response & converts it in to the form used by the controller.

Figure 3.2 closed loop control system

The first summing junction algebraically adds the signal from the input to the signal from the
output which arrives via the feedback path, the returned path from the output to the summing
junction. In the figure above, output signal is subtracted from the input signal. The result is
generally called the actuating signal.

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The closed loop system compensated for disturbances by measuring the output response, feeding
the measurement back through a feedback path, & comparing that response to the input at the
summing junction. If there is any difference between the two responses, the system drives the
plant, via the actuating signal to make correction. If there is no difference the system does not
drive the plant sincethe plants response is already the desired response. To compared between
open loop system & closed loop system; closed loop system has the obvious advantage of greater
accuracy than open loop system.

The system are less sensitive to noise, disturbance in the change in enviroment. Transient
response in steady state eror can be controlled more convinently& with greater flexibility in
closed loop system,often by simply adjutments of gain in the loop & sometimes by redesigning
the controller. insummery, systems that perform the previously described measurement &
correction are called cosed loop or feedback control system.

3.3 Problem Of The Statement

The present system, machines are can fill only a particular type of containers of certain

height, and the filling amount is as set by the operator. If the machine has to fill different type

(size) of container then again the operator has to set the filling amount for each container. Time

taken for filling will become more in such conditions. Sometimes in special environments which
are dangerous and not conductive for human operation, the operator cannot go and set the filling
amount.

Control system implies direct interaction with physical world. Control system includes sensor
and actuators, the critical pieces needed to ensure that our actuators system can help us manages
our activities and environments in desired ways. The sensor that will be implemented in this
project is infrared sensor. Nowadays, infrared sensor is widely used in daily activities such as for
security, memory detection and other proposes. Infrared sensor consists of two basic part; emitter
and detector. bottle movement on the conveyor belt. When the infrared sensor detected position
bottle, the motor of conveyor will be stop automatically.

Problem statements in this project are:

 To design a closed loop system which can control conveyor by sensor?

 To make sure that the bottle does not overflow and conveyor must stop as long as sensor
is working.
 To design conveyor system which limit the liquid flow into the bottles?

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3.4 Project Objective

3.4.1General Objective

To design plcBased automatic bottle filling and capping control system.

3.4.2Specific Objective

 To Design and Develop an Automatic honey filling to bottles of different height with the
PLC Integration.

 To develop an automatic bottle filling & capping system with a deductmechanismusing

sensors.

 The develop the system that use widely applicable low costly, familiarity sensor.

 To build a prototype which are light, low cost, user friendly and with transparentstructure.

 To develop a filling machine which can fill different sizes of containers on the bases
ofheight same principle can be used in different industries like medicine, oil,
chemicalindustries for filling liquid to different sized component by one machine.

 To automatic filling process for all bottles simultaneously with a user defined selectionfor
volume to be filled.

 To design a solution for a problem related to auto machine.

 To minimize errors, the control task should be defined by those who are familiar with
theoperation of the machine or the process.

3.5 Literature Review

3.5.1 History Of Bottle Filling And Capping System Based On Plc

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Long time ago people were using traditional method of filling fluid in to their containers and
caps them also traditionally. This was very time consumming work and consum energy to do the
work hardly.

Therefore, the machine filling system was introduced at near two decades ago. But, it was also in
efficient because, people were using to fill bottles or containers one after the other that it takes
time also. Recently up to now with the introduction of PLC and automation, people get more
excited by using them (PLC & Automation) to fills many containers as much as possible they
can, by using multi-filler and automatically filling machines. The work is the most efficient and
time saving in which it require only human to input (start) the process.

3.5.2 History Of Plc

PLC were first introduced in 1960‟s. the primary reason for such adevice was eliminating the
large cost involved in replacing the complicated relation based machine control system. Bedford
associates proposed something called amodular digital controller(MODICON) to major US car
manufacture. Other companies at the time proposed computer based schemes.one of which based
up on PDP-S. the MODICON OS4 brought the word‟s first PLC in to commertial production.

When aproduction requirements changed, so did the control sytem. This becomes very
expenssive when the change is frequent, scince relays are mechanical device that also have a
limited life time which required strict adhesion to maintenance schedule. Troubleshooting was
also quite tedious when so many relays are involved.

These “new controllers” also had to be easly programmed by maintenance are plant engineers.
The life time had to be long and programming changes easly performance. They also had to
servive the harsh industrial enviroment.

What is a PLC?

A Programmable Logic Controller, PLC is a digital computer used for automation of industrial
processes, such as control of machinery on factory assembly lines. It is designed for multiple
inputs and output arrangements.

A PLC is an example of a real time system since output results must be produced in response to
input conditions within a bounded time, otherwise unintended operation will result.

A PLC is a device that was invented to replace the necessary sequential relay circuits for
machine control. It works by looking at its inputs and depending upon their state, turning on/off
its outputs. The user enters a program, usually through software, that gives the desired results.
PLC are used in many “real world” applications. If there is industry present, chances are good
that there is a plc present. Almost any application that needs some type of electrical control has a
need for a PLC.

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A programmable logic controller, commonly known as PLC, is a solid state, digital , industrial

Computer using integrated circuits instead of electromechanical devices to implement control

functions. It was invented in order to replace the sequential circuits which were mainly used for
machine control. They are capable of storing instructions, such as sequencing, timing, counting,
arithmetic, data manipulation and communication, to control machines and processes. PLC have
many definitions for example: According to NEMA(National Electrical Manufacture‟s
Association ,USA),the definition of PLC has been given as “Digital electronic devices that uses a
programmable memory to store instructions and to implement specific functions such as logic ,
sequencing, timing, counting, and arithmetic to control machines and processes.”

Figure below illustrates conceptual diagram of PLC application

Figure 3.3 PLC conceptual application diagram

 Basic parts of PLC

All programmable controllers contain a CPU, memory, power supply, I/O modules, and
programmable devices. Basic parts of the PLC are as follows:-
 Processor
 Memory
 Input/output devices
 Programming panel or unit Power supply

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
Figure 3.4 Basic parts of PLC

 Operation of PLC
During program execution, the processor reads all the inputs, and according to control
application program, energizes and de-energizes the outputs. Once all the logic has been solved.
The processors will update all the outputs. The process of reading the inputs, executing the
control application program, and updating the output is known as scan. During the scan
operation, the processor also performs housekeeping tasks. The inputs to the PLCs are sampled
by processor and the contents are stored in memory. Control program is executed, the input value
stored in memory are used in control logic calculations to determine the value of output. The
outputs are then updated. The cycle consisting of reading of inputs, executing the control
program, and actuating the output is known as “scan” and the time to finish this task is known as
“scan time”. The speed at which PLC scan depends upon the clock speed of CPU. The time to
scan depends upon following parameter:-

 Scan rate
 Length of the program
 Types of functions used in the program

Faster scan time implies the inputs and outputs are updated frequently. Due to advance
techniques of ASIC (application specific integrated circuit) within the microcomputer for
specific functions, scan time of different PLCs have reduced greatly.

As PLCs have developed and expanded, programming languages have developed with them.
Programming languages allow the user to enter a control program into a PLC using an

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established syntax. Today‟s advanced languages have new more versatile instructions, which
initiate control program actions. These new instructions provide more computing power for
single operations performed by the instruction itself. In addition to new programming
instructions, the development of powerful I/O modules has also changed existing instructions.
These changes include the ability to send data to and obtain data from modules by addressing the
modules‟ locations. For example, PLCs can now read and write data to and from analog
modules. All of these advances, in conjunction with projected industry needs, have created a
demand for more powerful instructions that allow easier, more compact, function-oriented PLC
programs..

3.6 Methodology
This topic will mainly discuss about the methodology of the project and also the aspect or factors
that must be taken into consideration during the development process. All this factors were very
important to make sure the project will achieve its objective.

3.6.1 Project Over View

In this section, we will discuss an over view of Automatically Filling Bottles and Capping system
using PLC. The introduction to system task will also briefly explain.

 Input Module

Input Module in other word are Sensors. Such a sensors includes: The present and Absence of the
bottles checker, whether the bottles has any crack around it next (in case of glass bottle), The
Sensor that check the cleanness of the bottles, or In general the input modules are all necessary
sensors in different place. At the Filling system we have a sensor that detect whether the bottle is
full or not, this can be either Weight Sensor or Level Sensor. IR Sensor (Photo Sensor) is used at
the start of the system to detect whether the bottles are ready to move to the filling system or not.
At this point when IR (Photo sensor) detect the position of the bottles the Motor will be ON and
the Conveyer start taking bottles to the filling station.

For a multi filler machine at one, each filler have their own sensor detecting whether the bottle is
to be filled or not. Then the filling take place, and the Weight sensor (Level sensor) will take part
to tell whether the bottle is full or not.

The following are the input modules (Sensors):

 Infrared Sensor
 Weight Sensor
 Limit switch
 Proximity

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  Infrared Sensor ( IR )

This sensor provides the system with ability to detect the presence of object position. The theory
is the IR emitter emits infrared light. If an object presence the signal will be reflected back to the
receiver. Then the IR detector implemented will detect the reflected light. Then the
correspondence signal sends to the PLC for being analyze. Based on the measurement of the
intensity of the reflected light from the target area such a bottle, it has a light source sending light
to the moving target and a light sensor receiving the light. The output signal from the sensor
decreases exponentially with the increase of the distance to the measured object. Infrared light-
emitting diodes (LED's) and photosensitive diodes are used in this transducer. The sensor output
is inversely proportional to the amount of occupation. A multilink array of light sensitive
elements and a light-beam scanning technique determines and qualifies the shape of the
measured object by processing data from the elements.

 Limit Switch
The limit switches needed to detect the arrival of the bottle to the desired position to do the
processes such as filling and capping. Here we need two limit switches, one to detect the bottle
arrival to the end of the first conveyor belt and the other to detect the bottle arrival to its filling
position. The limit switches are mounted at the edge of the conveyor.

 Signal Conditioning

As the output of sensor are not always given directly to the PLC, and the input voltage should be
24V. Therefore, they should be given through what so called Signal Conditioning circuit which
condition the input signal and in turn give it as an input to the PLC. As to save our work they
should be directly given to the PLC, rather through the Relay circuit that has three terminals NO,
NC and COMMON terminals. The 24V to the PLC should be in a common terminal of the relay.
Then depending on the signal, the circuit close or open there by connecting to the PLC.

 Output Module

The various output devices used in the bottling process are gear motors, pumps, actuators. The
gear motor is used to run the conveyor in forward direction. Actuators are used for capping the
bottles. The actuator applies a force on the caps which in turn corks the bottles tightly. These are
the various output devices used in the bottling process.

The output modules are:

 DC motor
 Conveyer belt

 Dc Motor

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DC Motor is an electromechanical device that can move if the power supply is connected. It
main function is to make the Conveyer belt moves perfectly. There are many types of DC Motor
at market place such as: Gear dc motor, Servo motor, stepper motor….etc. for the time being we
used Gear dc motor for our project.

 Conveyer Belt

The first conveyer belt that carries the bottles to the track to be filled will be made of PVC
(polyvinyl Chloride) to allow for the bottle to slip if it hits the ratchet while another bottle is still
waiting to be grabbed. Also, this will enable us to use a DC motor with relatively small output
power and low speed. The second conveyer belt will be made out of rubber because we need
relatively high coefficient of friction with the bottle to prevent slippage. The motor used here
will be also a DC motor with relatively low speed‐torque capabilities. This is because the load on
the conveyer belt will be low. The diagram blow is the flowchart diagram of the System entirely
containing sensors & processes.

3.7System Model (Block Diagram)

Figure 3.5 Block Diagram of Bottle Filling System

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3.8 Flow Chart Of The System

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Figure 3.6 flow chart diagram of the entire system

When the start button is pushed the motor starts hence the conveyer belt starts moving.When the
bottle is under the solenoid valve, the bottle is sensed and the motor hence theconveyer belt
stops. Then the solenoid valve operates and the bottle starts filling with water.

When the bottle is filled then the solenoid valve is closed and the motor hence the conveyer belt

start moving and carrying the bottle away from the solenoid valve . If there is any bottle present

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in capping machine then the capping machine is cap the bottles. When the bottle capped the

motor and conveyer belt start moving. If another bottle is sensed then the above process will be
repeated. When stop button is pushed then the entire process will be stopped and reset the circuit.

3.9 Process Description

This seminar gives a detailed explanation of the various processes taking place in a

complete bottling system. The filling and capping operations take place in a sequential manner.

When no bottles are kept in the input the system is reset. Depending on the number of bottles fed
into the input side, the corresponding bottles are filled and capped.

3.9.1 Hardware Part:

Our proposed device is consisted of a PLC (LOGO 230 RC), 24V DC Relay, 220V AC

Relay, Sensor, Solenoid valve, Gear motor, Conveyer belt, 24 V DC Source, ON-OFF button and

some connectors. The ON-OFF button Works as the input device. The PLC controls the input

and output according to the program provided to it.

 Solenoid Valve

It is an electromagnetic valve used to control various types of liquids by opening and closing
automatically. Various types of applications are performed by using this solenoid valve.

3.9.2 Software Part:

In software part we are going to discuss about the programs and the logics used. There

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are some programming languages for control systems:

 Block diagram (BD)

 Ladder diagram (LD)

In our proposed device the Ladder Diagram (LD) is used. This is to interface the ONOFF

button, programming logic. There are several programming software’s available but in our

device ladder logic is used. It is easy to understand and the programming is made more flexible

to users.

 Ladder logic

Ladder logic is the main programming method used in PLC. Ladder logic is based on

mimic relay logic. The relay logic diagrams are difficult, hence we have selected ladder logic as

main programming method. In modern control systems they used relay but these are not used for

logic. A relay is a device that controls a switch using magnetic field. Relays are used as one
power source close a switch for another power source, while keeping isolated.

3.10 How System Works

3.10.1 Bottle Detection Using Sensor

Bottles are kept in position in their respective holders which are fixed to the Conveyor at

the input side. IR sensors are used to detect the presence of bottles in the holder. Depending on

the output of the sensors the filling and capping operation takes place. A time delay is given in

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order to set the status of the bottles. If bottle 1 is present the corresponding Status bit in PLC is

set to 1 else it is set to 0. The outputs of these sensors are given to the PLC and depending on this

output the filling and capping process for the bottles takes place. Thus if all the n bottles are

present in the input side then the sensor gives the corresponding output to the PLC which in turn

switches ON the corresponding pumps for filling operation to take place. If a Particular bottle is

not present the corresponding pumps remain OFF.

3.10.2 Filling Operation

Once the bottles are detected in the input side the conveyor motor switches ON and it

starts moving in the forward direction. The bottles then reach the desired position for Filling and

the conveyor stops. The corresponding pumps in process tank switch ON and filling Operation

takes place. For e.g. if only bottle 1 is present then pump 1 switches ON and pump 2 and pump 3

remain switched OFF. There are three tanks present in the filling side namely: process tank,

concentrate tank (tank 1) and tank to store water (tank 2).Tank 1 and tank 2 have low level and

high level sensors (LLS and HLS) respectively. Process tank has three level sensors (LLS, HLS

and MLS).MLS is used to denote the middle level of the tank. When the liquid in the process

tank reaches below low level (LLS) pumps in tank 1 and tank 2 switches on and the process

tanks get filled. When the level of liquid reaches high level (HLS) the pumps in tank 1 and 2

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switch off.

3.10.3 User Defined Wight

The filling operation is accompanied with a user defined weight selection menu. The

desired weight is fed into the PLC and depending on the weight the filling of honey takes place.

The filling is done using timing operations. Thus the pump remains on for the preset value of the
timer and switches off once time is out. Once the filling process is done the conveyor starts
moving again.

3.10.4 Capping Operation

The bottles are transported to the capping arrangement. IR sensors are kept to Stop the

bottles in the desired position for capping to take place. Once the bottles reach the Position the

conveyor motor switches OFF. The capping of bottles is done using actuator arrangement. Three

actuators which move in forward and reverse directions are used to cap the Bottles. The actuator

applies a force on the caps which are placed in their respective holders. This Force helps the caps

to fit into the bottles at the required position. Similar to filling, if a particular bottle is not present

it does not get capped. Thus the capping is done and the conveyor starts moving again. When the

capping operation for one batch is done simultaneously the filling operation for another batch

takes place. The entire sequence of operations continues until there are not bottles present in the

input side. All these are automatically coordinated using the PLC. PLC gets the input from the

input devices and sends the signals to the various output devices Depending on the conditions

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that are fed into the PLC. Thus bottles get filled and capped.

3.11 Input And Output Assignment

3.11.1 Input Assignment

Table 1 input addressing and their comments

Name Address Comment
Start I0.0 Start push button to start the
conveyer by means of motor 1
Stop I0.1 Stop push button for stopping
the operation of the whole
system.
Infrared ray sensor 1 (IR1) I0.2 To indicate whether the bottles
are present, have a crack, and
they are cleans.
Limit Switch 1 I0.3 To indicate whether the bottles
reached the place where to be
filled or not.
Weight sensor(Comparator) I0.4 To indicate whether the bottle
is filled or not
Limit switch 2 I0.5 To indicate whether the bottles
reached the place where to be
capped or not.
Infrared ray sensor 2 (IR 2) I0.6 To sense the capping of the
bottle
Infrared ray 3 (IR 3) I0.7 This IR sensor is used to
detect whether the covered
bottles are uplifted or not.
ON delay timer T37 For the continuity of the
process(to recycle the entire
system)

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3.11.2 Output Assignment

Table 2 output addressing and Address Function

their function Name
Motor 1 starter coil Q0.0 Used to start the motor 1,
energized by the coil when it
gets signal from input I0.0.
Conveyer belt 1 Q0.1 To transport the bottle when
motor 1 is energized
Lifting motor Q0.2 Used to uplift the bottle
towards the desired place of
filling.
Bottles filler Q0.3 To fill the bottle.
Motor 2 starter coil Q0.4 Used to start motor 2
energized by the coil after gets
a signal from an input I0.4.
Conveyer belt 2 Q0.5 To transport the filled bottle
for a capping towards a
capping machine
Capping machine Q0.6 To cap a filled bottle
Motor 3 starter coil Q0.7 Used to start the motor 3
energized by the coil when it
gets a signal from input I0.6.
Conveyer belt 3 Q1.0 To transport the filled and
capped bottle to the place
where taken by a person from
the system

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3.12 Result And Discussion

Figure 3.7 Network 1 & 2 of the system

These network(.i.e. the above one)contains I0.0,I0.1(start push button and stop push button
respectively).This input signal energizes the coil for the starting of the motor 1 to bring the
conveyor1 which carries the bottle for the coming filler. It also contains T37 for recycling of the
system.

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Figure 3.8 Network 3-5 of the system

Network 3 It contains a sensor called infrared ray 1 (I0.2) which is functional for the detection
of the presence, cleanness, and cracking of the bottle and give an input signal to a coil to be
energized and uplifted by the machine. Network 4 This network contains I0.3 which sense
whether the required bottle is ready to be filled by the filler machine and I0.4 for the detection of
bottle whether the bottle is filled or not. Network 5 and 6 It contains input I0.4 which give an
input signal to energize the coil that starts the motor 2,which makes conveyor 2 to start moving.

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Figure 3.9 Network 6-8 of the system
Network 7 In this network we have a sensor called proximity sensor (I0.5) which is used to
check whether the filled bottle is ready to be capped. Network 8 and 9 This contain sensor
Infrared ray IR 2 (I0.6) which detect the bottle whether it is capped or not to give an input signal
which makes a coil inside a motor 3 energized. This brings the motor 3 to be starts working and
next the conveyor 3 moving.

Figure 3.10 Network 9 & 10 of the system

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Network 10 Contains a sensor called infrared ray IR 3 (I0.7) Which senses the uplifting of the
filled and the capped bottle by a manual and also a timer called T37 which is functional for the
continuity of the system.

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3.13 The Overall System Ladder Diagram

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CHAPTER-FOUR

OVERALL BENEFITS GAINED FROM THE INTERNSHIP

PROGRAM

The four months internship program has many benefits. Hence it enables to relate the theoretical
knowledge with the practical one. And it guides me to decide my future job in which ways and
companies should be. In addition of this it improves the capacity how to face challenges and
identify any company’s problem that decreases the productivity of the company. Generally I have
gained benefits from internship in terms of:
 Improving practical skills
 Upgrading theoretical knowledge
 Improving interpersonal communication skills
 Improving team playing skills
 Improving leader ship skills
 Understanding the work ethics
 Improving entrepreneurship skills
Improving Practical Skills

i have got a lot of practical experience while i were trying to troubleshoot and in maintaining
during systems come across problem. Also i have got an opportunity to work on the
equipment’s which only i know theoretically those special electronics components, electrical
machinery and some other equipment which i were not able to see and work on them in my
regular laboratory session.

4.1 Upgrading Theoretical Knowledge

I am also upgrading my theoretical knowledge in relation to the materials that dimma honey
processing plc company used. And also by the help of the workers and the manuals found in
dimma honey processing plc company i got additional theoretical knowledge related with my
study.

4.2 ImprovingInterpersonal Communication

We develop our communication skill by communicate with our work mate for the last four month
and students came from other universities for internship based on our study.

4.3 Improving Team Playing Skills

i usually work in a team with at least one responsible person assigned by my supervisor which
forced me to spend much time in a team. Most of the time while I am trying to
troubleshoot i discuss in team to provide solution to a give problem that also contribute to me to

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work in team and also increase my interpersonal communication skill. So team work gave us the
opportunity to share what i know with each other and also gave us opportunity to gain a lot of
theoretical and practical knowledge from staffs on the factory and also from students from
another university.

4.4 Improving Leadership Skill

My ability to lead is improved as sometimes given an opportunity to lead troubleshooting a
given problem with each other of my group members and sometimes with electricians. So, my
leadership skill is improved which forced us to act responsibly.

4.5 UnderstandingWork Ethics

Internship program helped me to understanding work ethics such as;

 Strictly following rule and regulation of the factory.

 Availing ourselves on time.
 Give all cares for the staff while communicating.
 Handling all equipment’s in right way not to damage the nature of the equipment’s and
miss-management of resources.

4.6 ImprovingEntrepreneurship Skills

Internship practice can be also improving entrepreneur ship skills. So, my skill is improved in
terms of taking risk for all own works. In addition to those mentioned benefits, internship is
used to cause people from different places know one another and share their experiences.

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 CHAPTER -FIVE

Conclusion and Recommendation

5.1 Conclusion
In the four months I got technical knowledge and i integrate theoretical knowledge with practical
knowledge.
The theory and concept of the automatic filling and capping system is based on the PLC control
system. In PLC design, the features and functions of the PLC components are required to
determine the system function. Furthermore, the theoretical of the wiring system is required for
connecting the inputs and outputs devices to PLC. In programming design, understandings of the
desired control system and how to use the Ladder Diagram to translate the machine sequence of
operation are the most important parts, because it have direct effect on the system performance.
The main aim in this process is to apply PLC to design automatic filling and capping system and
all objectives in this project were successfully done as planned. Finally, the basis control system
and logic design apply in this project can be used as a references to design other applications of
automation system, and also can be used as a teaching material for the Industrial Control subject.

Generally, internship provides me with valuable insights in to the professional and industry
oriented side of my field of study .it enable me to put into practical skill, techniques and
knowledge that are important for my success in my future work place. It also helps me to
identify title for my final project work.

5.2 Recommendation
I have recommended for the company as fellow.
Recommendation to the company
 I recommend to the company that firstly the company should accept students for the hosting
as far as possible its capacity and capabilities needs to give them enough practical and
professional skill, techniques and knowledge for their future success in work area. Besides
that it should fulfill facilities (service and canteen: For instance safety materials, computer
service were not available at that time, service of transport is not fully allowed) and working
cloths for better safeguard like the normal clients.
 And also it has no full documented data.


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REFERENCES
[1] Siemens. „Basic of PLCs‟ STEP 2000 series, Siemens Technical Education Program.
[2] Norman S. Nice „Control System Engineering ‟. Third Edition.California State Polytechnic
University Pomona. John Wiley & Son, Inc, 200
[3] Colin D. Simpson„Programmable Logic Controllers Regents‟ Prentice Hall.
 [4] Noel M. Morris„ Control Engineering‟ Mc GRAW-HILL Book Company (UK)
Limited.
[5] Lug, J. Y. S., Walker, M. W., and Paul, R. P. (1980b). Resolved-Acceleration Control of
Mechanical Manipulators.IEEE Trans. Automatic Control.
[6] Bateson, N.R. Introduction to Control System Technology, Sixth Edition, United State of
America: Prentice Hall.1999.
[7] Manual book, „ A Beginner‟s Guide to PLC‟,version 2.1. Singapore: Omron.2001.

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