Abstract: Modern manufacturing in industries such as beverages and pharmaceuticals relies heavily on automated filling and capping machines to ensure high throughput and consistency. This paper presents a PLC-controlled bottle filling and capping system, Size-Shift Fill-Cap, which adapts to multiple bottle sizes without manual changeovers. The system uses integrated sensors to detect bottle dimensions and automatically adjusts the filling nozzle height and volume, as well as the capping mechanism, for three bottle sizes. A Programmable Logic Controller (PLC) coordinates the sequence in real time, while an HMI (Human-Machine Interface) allows operators to calibrate fill volumes and timings for each size. The prototype achieved precise filling and secure capping across all supported bottle formats. Testing demonstrated improved efficiency, with reduced cycle time per bottle compared to manual operations. The machine’s flexibility, ease of use, and safety features highlight its potential to streamline bottling processes and reduce downtime during product changeovers.

Keywords: Automated Bottle Filling, Capping Machine, Programmable Logic Controller, Multi-Size Adaptability, Industrial Automation, Human-Machine Interface

Pages: 435-444