PLC and SCADA based Industrial Automated System

In every process industry, there is a repetition of the tasks. So, in order to get the better productivity in limited time with lesser error probability, we are incorporating Automation into the process industries. In recent trends of automation like Industry 4.0, manual operations are being replaced with fully or semi auto-controlled, reconfigurable operations by incorporating more advanced technologies. Primitive methods of filling of different types of liquids in a fixed proportion in different containers or bottles involve manual operations. This hampers production rate and sometimes quality of product consistency due to the involvement of human intervention. In this paper, a simulated prototype of SCADA (Supervisory Control and Data Acquisition) and PLC (Programmable Logic Controller) based process of bottle filling in beverage industry is designed to fill the different types of containers with different composition of liquids. The entire simulated operation involves distinct stages of sorting the containers, filling liquids, capping, labelling of different containers and counting the units per batch. The Metallic base and Non-Metallic bottles are sorted by assistance of Inductive Proximity Sensor. During filling stage, the Metallic base bottle is filled with each of the available three different liquids composition equally and the Non-Metallic bottle is filled only with two initial type of liquids composition. In later stages, bottles are labelled separately. Both type of bottles are detected with the help of Photo-electric Retroreflective type sensors at Filling, Capping and Labelling stages.