FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL & MECHATRONICS ENGINEERING 
Liquid Food Packaging and Filling Line

Supervisor:
Dr.Bashir Nouri 

Group Members:
Ibrahem Jauysi          (12028740)
Ayesh Khatatbe         (12028841)
Nabil Masood            (11924352)


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Contents






🟡Introduction 
🟡Motivation
🟡Literature Review
🟡Model Design
🟡Electrical Design
🟡CONTROL Design
🟡Testing and Implementation
🟡FeasibilityStudy
🟡Conclusion & Recommendations





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Introduction 
overview of the Project:
🟡Designing an automated liquid food packaging and filling line.
🟡Focus on efficiency, precision, and compliance with regulations.

Key Goals:
🟡Enhance production throughput.
🟡Maintain regulatory compliance under food safety standards.
🟡Improve quality control and operational efficiency.
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Motivation

🟡 Increased Demand
 The growing need for bottled beverages and sauces drives innovation in filling systems.
🟡 Efficiency & Automation
 The importance of efficient and automated systems to meet production demands.
🟡 Sustainability
 A focus on eco-friendly practices to ensure sustainable food packaging.
🟡 Food Safety Standards
 Compliance with strict regulations to guarantee food safety and hygiene.



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Motivation
Objectives
🟡 Waste Reduction
 Reducing material waste and lowering operational costs.
🟡 Improved Quality
 Enhancing product shelf life and maintaining high-quality standards.
🟡 Automation Focus
 Minimizing manual labor while increasing automation for greater efficiency.

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Challenges



🟡 Precision in Liquid Filling – How to ensure accurate volume per bottle?

🟡 Synchronization of Motors – Achieving smooth coordination between components.

🟡 Choosing the Right Control System – PLC or Microcontroller?

🟡 Ensuring System Efficiency & Stability – Reducing errors and optimizing performance.



6



Literature Review



Key Topics:
🟡Food packaging and filling technologies.
🟡Classification of food products (liquids, semi-liquids, powders).
🟡Components of food filling production lines (hoppers, conveyors, nozzles).
Insights:
🟡Analysis of current technologies and market trends.
🟡Focus on automation and integration.

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Model Design
Materials:
🟡Stainless steel for durability, hygiene, and resistance to corrosion.




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Model Design

Core Components:
🟡 Hopper: Conical shape, 30L capacity, designed for smooth discharge.

🟡Screw Pump: Positive displacement pump for viscous liquids.



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Model Design




🟡Filling Nozzle: Ensures accurate and drip-free dispensing.

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Electrical Design



🟡Main Components:


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Electrical Design

🟡 DC Motor: For continues mixing through the process. 

🟡Stepper Motor: For precise movement of the screw pump.


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Electrical Design
🟡Sensors: Includes Fischer NC57 capacitive level sensor for monitoring.

🟡 Laser & LDR modules: They are used to detect the containers.

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Electrical Design



🟡Servo motors: Used to move the conveyer belt, also for the nozzle.  
🟡 Arduino Uno Microcontroller: Central control unit.
🟡Power Supply: Regulated to ensure stability and efficiency.


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CONTROL DESIGN



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Operational Workflow:


🟡 The system starts by transporting empty containers via the conveyor.


🟡 The pump is activated to fill the container with the specified amount upon detection.


🟡 The mixer speed is controlled to ensure product consistency.


🟡 The nozzle valve is precisely operated to prevent dripping and ensure process cleanliness.



Testing and Implementation



🟡 Assembled key components and integrated control system
🟡 Achieved high filling accuracy for labneh
🟡 Filling Accuracy: ±4% deviation from the target
🟡 Cycle Time: 5 ~ 6 seconds per fill
   Modifications Implemented:
🟡 Reduced peristaltic pump speed → minimized foaming
🟡 Adjusted nozzle motor position → improved sealing
🟡 Added temporary mixing cycle → lowered power consumption

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Machine Analytics
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Performance Analysis:


Efficiency metrics: Reduced waste, optimized throughput.


Energy consumption: Focus on sustainability and cost reduction.


Data Insights:


Real-time monitoring through sensors.


Feedback loops for improved accuracy and reliability.






Feasibility Study
🟡 Technical: Precise filling (±1%) and reliable, low-maintenance operation
🟡 Economic: Budget-friendly (~1650 USD) with 2–3 months payback
🟡 Operational: Easy to use, 96% accuracy within ±4% error
🟡 Legal: Fully compliant with food safety regulations
🟡 Environmental: Low energy use, minimal waste, and easy to clean

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Conclusions & Recommendations
🟡 Proven technical effectiveness and real-world potential
🟡 Successful integration of key systems: mixing, pumping, valve control
🟡 Cost-effective, hygienic, and modular solution for small/medium dairy producers
🟡 Recommendations: Enhance materials, automation, hygiene, safety, and calibration
🟡 Future Work: Focus on full automation, energy efficiency, and global certification

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Thank You








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