Automation of Cupcake Filling System for Small Scale Industries using PLC

Manual cupcake filling processes in small-scale industries often result in increased raw material wastage, inconsistent output, and higher production times. To overcome these challenges, this project presents an Automated Cupcake Filling System using a Siemens S7-1200 PLC. The system integrates a conveyor mechanism, a capacitive proximity sensor for precise cup detection, and a 12V DC wiper motor for accurate batter dispensing. Ladder logic programming in TIA Portal ensures synchronized operation between cup detection, filling, and conveyor movement. By automating the filling process, the system significantly reduces material wastage, improves production efficiency, and minimizes human intervention. The inclusion of IoT-ready PLC capabilities further enables future scalability for remote monitoring and control. This solution demonstrates a cost-effective and sustainable approach to enhancing productivity and operational consistency in small-scale food manufacturing industries.