Design and Simulation of an Automated Bottle Filling and Capping System Using a Siemens PLC Training Kit

Filling and capping are basic operations in beverage, food and pharmaceutical packaging and a classical example of sequence control. This paper presents the design and simulation-based evaluation of an automated bottle filling and capping system controlled by a Siemens PLC training kit. The control program coordinates bottle detection, conveyor motion, liquid dispensing and cap placement as a chain of interlocked steps, together with emergency-stop and fault handling. The evaluation by numerical simulation covers filling accuracy, cycle time and capping success rate. In the simulated station the mean filling error was -0.46 mL (SD 6.73 mL) for a 250 mL target, with a cycle time of 19.2 s per bottle and a capping success rate of 98.7 %.