Automatic Bottle Filling System using PLC

Automatic Bottle Filling System using PLC

Filling machines are devices used in the packaging business to fill containers with liquids, gases, pastes, or powder. Bottles loaded with substance are capped using capping machines. As a result, we’ve created a system that uses PLC and mechanical assembly to show the filling and capping of bottles in industries.

The filling is done using a piston and syringe system, and capping is done with a motorized system, all in one machine. A conveyor pulls empty bottles towards the filling head, which is the center of the assembly. The filling head is in charge of filling bottles with water; after that, the assembly pushes the bottle via a circulating disc, which transports it to the capping station, where the bottle is capped.

The bottle that makes it to the cap turning station, which is a motorized device that spins and tightens bottle caps. The assembly then moves the bottle to the next phase, where it is rolled down the system as a finished product. The entire system is controlled by a PLC-based system that uses sensors and motorized components.

Automatic Bottle Filling System is one of the example in PLC program using RSLOGIX 500.

Bottle Filling System

Problem Logic

Step Conditions:

  1. The start and stop buttons on the PB are used to initiate and terminate the process
  2. The Start button is pressed. The conveyor will not move until the proximity sensor is turned on.
  3. After that, the solenoid valve is left open for 5 seconds. Conveyor should start moving after 5 seconds.
  4. The process should be repeated until three bottles have been filled.
  5. While the stop button is pressed, the process should continue.

List of Inputs and Outputs

PLC Program

Program Description

RUNG 0000

The system is controlled by a latching rung via the Master Start and Stop PB.

RUNG 0001

Memory bit (B3:0/1 ) is utilized to turn on the conveyor motor.

RUNG 0002

When you use the memory bit of start latching PB and B3:0/1 to turn on the conveyor motor, it will immediately turn off when B3:0/2 turns on after the proximity sensor is activated.

To turn the conveyor motor back on, a timer is connected in parallel.

RUNG 0003

The output of the proximity sensor is recorded in the memory bit for usage in the previous rung.

RUNG 0004 and Rung 0005

Comparator block is used to compare counter accumulator value to terminate the process once three bottles have been filled to save the status of proximity sensor B3:0/3.

Rung 0006

A proximity sensor is attached to the up counter with a preset value of 3 to count the number of bottles.

RUNG 0007

The counter is reset using the stop input.


  1. The sensor output is stored in memory bits; however, because this is a simulation, the sensor cannot turn off automatically.
  2. 2.The sequence of operations is determined by memory bits.


The simple bottle filling method described above is merely an example. It may differ from the current time.

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