COIMBATORE INSTITUTE OF TECHNOLOGY,
COIMBATORE-14
DE
DEPARTMENT OF ELECTRICAL AND ELECTRONICS ENGINEERING
AUTOMATIC BOTTLE FILLING SYSYTEM USING ARDUINO
TEAM MEMBERS
ANBUMANI V-2303717610521066
GOKUL S-2303717610521075
HEMANTH KUMAR S-2303717610521081
SANJAY KAVIN M-2303717610521108
ASVIN SHARATH M - 2403717610521306
DATE OF SUBMISSION
17-10-2025
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Executive Summary
The project titled “Automatic Bottle Filling System Using Arduino” aims to design and implement a low-cost,
efficient, and automated bottle-filling mechanism suitable for small-scale industries. The system utilizes an
Arduino Uno microcontroller as the central control unit, integrated with IR sensors, a stepper motor, solenoid
valve, and relay driver circuits to automate the bottle filling process.
The system operates by detecting the presence of a bottle on a conveyor belt through an infrared (IR) sensor.
Once detected, the Arduino halts the conveyor using the stepper motor driver and activates the solenoid valve to
dispense liquid into the bottle for a pre-defined time. After the filling process, the valve closes and the conveyor
resumes movement, allowing the next bottle to be filled automatically. This cycle continues without human
intervention, demonstrating the principle of industrial process automation.
Key components such as the A4988 stepper motor driver, IR sensor module, and relay interface ensure accurate
control, timing, and safety of the operation. The report also elaborates on the technical specifications and
working principles of these components, highlighting their role in the automation sequence.
This project provides a cost-effective and educational prototype that mirrors the functionality of industrial PLC-
based filling systems. It showcases the potential of microcontroller-based automation in manufacturing,
packaging, and beverage industries.
Overall, the project successfully achieves its objective of developing a reliable, programmable, and automatic
bottle filling system using basic electronic components and embedded control principles.
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TABLE OF CONTENT
S.NO SECTION TITLE PAGE NO
1 Introduction 4
2 Literature Review 4
3 Objectives and Scope 5
4 System Architecture 6
5 Methodology and Implementation 6
6 Mathematical Modeling and Analysis 8
7 Budget and Cost Analysis 9
8 Risk Assessment 10
9 Benefits and Applications 10
10 Evaluation and Testing Plan 11
11 Future Scope 11
12 Conclusion 11
13 References And Appendices 11
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1. Introduction
In today’s industrial era, automation has become an essential part of modern manufacturing and production
systems. Industries are increasingly adopting automated processes to improve efficiency, accuracy, and
productivity while minimizing human errors and operational costs. One such application of automation is the
bottle filling system, which plays a vital role in packaging industries such as beverages, pharmaceuticals,
chemicals, and food processing.Traditionally, bottle filling operations were carried out manually, which
required continuous human supervision, leading to inconsistencies, wastage, and slower production rates. To
overcome these limitations, automated bottle filling systems have been developed, utilizing sensors and
controllers to ensure precise and efficient filling operations.
The Automatic Bottle Filling System using Arduino is a cost-effective prototype that demonstrates the working
principle of an automated filling process. The system uses Arduino Uno as the main controller, which
coordinates the operation of components such as an infrared (IR) sensor, stepper motor, solenoid valve, relay
module, and motor driver.The process begins with a conveyor belt that moves bottles toward the filling station.
When an IR sensor detects the presence of a bottle beneath the nozzle, the Arduino temporarily stops the
conveyor, activates the solenoid valve to dispense a measured amount of liquid, and then resumes conveyor
motion to position the next bottle. This ensures uniform filling levels and uninterrupted production without
manual intervention.
This project provides a simple yet practical approach to understanding industrial automation using
microcontrollers. It integrates electronics, sensors, and control logic to mimic real-world automated systems
used in production lines. Moreover, it emphasizes the importance of programmable control in achieving
reliability, flexibility, and repeatability in industrial applications.Thus, the Automatic Bottle Filling System
using Arduino serves as an excellent educational model that bridges theoretical knowledge and practical
implementation, demonstrating how embedded systems can effectively replace manual labor in industrial
processes.
2. Literature Review
Automation has become a cornerstone of modern industrial systems, enabling higher productivity, precision, and
reliability. Over the past decade, numerous studies and projects have explored the design and development of
automatic bottle filling systems using various control platforms such as Arduino microcontrollers, Programmable
Logic Controllers (PLCs), and embedded control circuits. Many researchers have focused on low-cost automation
prototypes using Arduino because of its simplicity, open-source environment, and ease of interfacing with sensors
and actuators. These systems typically employ infrared (IR) sensors or ultrasonic sensors to detect the presence of
a bottle on a conveyor belt, while solenoid valves or pumps are used to dispense the liquid in measured quantities.
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In a number of student projects and academic papers, IR sensors have been identified as a reliable and economical
solution for object detection, particularly in applications like bottle filling, sorting, and packaging. Ultrasonic
sensors are also used where non-contact distance measurement is required, especially for liquid level detection
and volume control. For actuation, solenoid valves are preferred due to their simple on–off control and quick
response time, though industrial systems often integrate flowmeters or peristaltic pumps for more accurate
volume measurement. Studies comparing PLC-based systems with Arduino-based models highlight that while PLCs
are more robust and suited for industrial-scale operations, Arduino provides a flexible and cost-effective platform
for educational and small-scale automation projects.
Literature on stepper motor control and conveyor mechanisms shows that precise bottle positioning is achieved
using A4988 or DRV8825 stepper motor drivers, which ensure smooth and accurate conveyor movement.
Researchers have also emphasized the role of relay modules in isolating low-voltage control circuits from high-
voltage actuators, ensuring safety and circuit protection. Industrial research further indicates that advanced filling
systems use electronic flowmeters, pressure sensors, and synchronized multi-head mechanisms to improve speed
and accuracy. Recent developments have integrated IoT and SCADA systems for remote monitoring, data logging,
and predictive maintenance, demonstrating the evolution toward smart manufacturing.
Despite these advancements, gaps still exist between educational prototypes and full-scale industrial
implementations. Arduino-based systems often rely on time-based control, which may result in small inaccuracies
due to variations in liquid pressure or viscosity. To address this, several studies recommend integrating feedback
mechanisms such as flow sensors or load cells to achieve closed-loop control and consistent filling volumes.
Nevertheless, for learning and demonstration purposes, Arduino-based automatic bottle filling systems remain one
of the most effective and accessible ways to understand the principles of industrial automation, sensor integration,
and embedded system design
.3. Objectives and Scope
Objectives:
• To build a simple and low-cost automatic bottle filling prototype.
• To use an IR sensor to detect when a bottle is in position for filling.
• To control a solenoid valve for pouring the right amount of liquid into the bottle.
• To move bottles automatically using a conveyor belt driven by a stepper motor.
• To reduce human work and improve speed and accuracy in the filling process.
• To learn how Arduino can be used for automation in industries.
• To make a model that can be upgraded for future industrial use.
Scope:
• Multiple filling nozzles for faster operation.
• Liquid level sensors or flow sensors for better accuracy.
• PLC or IoT control for industrial-level monitoring and automation.Scope
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4. System Architecture
• Control Unit:Arduino Board: This serves as the central processing unit, receiving input from sensors,
processing data, and sending control signals to actuators. Common choices include Arduino Uno or
Nano due to their versatility and ease of use.
• Sensing Unit:Bottle Detection Sensor: An IR sensor or ultrasonic sensor is commonly used to detect the
presence of a bottle on the conveyor belt or at the filling station.Liquid Level/Flow Sensor: Depending
on the filling method, a flow sensor (e.g., YF-S201) can measure the volume of liquid dispensed, or a
liquid level sensor can detect when the bottle is filled to a desired level.
• Actuation Unit:Conveyor Belt Motor: A stepper motor or DC gear motor drives the conveyor belt to
transport bottles to the filling station.Motor Driver: An A4988 driver (for stepper motors) or a relay
module (for DC motors) is used to control the motor's speed and direction based on Arduino
signals.Solenoid Valve/Pump: A solenoid valve or a water pump (controlled by a relay) is used to
dispense the liquid into the bottles.
• User Interface/Feedback Unit (Optional):LCD Display: A 16x2 LCD can provide real-time status
updates, such as "Filling in Progress,Fill Complete, or current volume dispensed.Buzzer/LEDs: These
can provide audible or visual feedback for events like fill completion or system errors.Keypad/Buttons:
A keypad or simple buttons can allow for user input, such as initiating the filling process or selecting
different filling volumes.
• Power Supply:A suitable power supply unit provides the necessary voltage and current for the Arduino,
motors, sensors, and other components.
5. Methodology and Implementation
Design Stage:
The system is designed with four main units – sensing (IR sensor), control (Arduino), actuation
(motor and valve), and power supply.
Hardware Setup:
• IR sensor detects the bottle.
• Stepper motor drives the conveyor through an A4988 driver.
• Solenoid valve, controlled via a relay, regulates the liquid flow.
• Arduino coordinates all operations based on sensor inputs.
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Software Development:
• Arduino is programmed to:
• Continuously monitor the IR sensor.
• Stop the motor when a bottle is detected.
• Open the valve for a preset filling time.
• Restart the conveyor for the next bottle.
Testing:
The system is tested for timing, synchronization, and fill level accuracy. Adjustments are made by changing the
delay time in the Arduino code.
Block Diagram
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6. Mathematical Modeling and Analysis
1. Flow Rate Model
The amount of liquid filled depends on the valve open time:
Q=R*T
Where
Q = Volume filled (ml)
R = Flow rate of valve (ml/s)
T = Valve open time (s)
2. Conveyor Speed
The conveyor motion driven by the stepper motor is given by:
V=(S*θ)/360
Where
V = Conveyor speed (cm/s)
S = Steps per second
θ = Step angle (°)
3. Control Logic
If the IR sensor detects a bottle:
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→ Motor OFF, Valve ON
Else:
→ Motor ON, Valve OFF
4. Key Parameters
Filling Accuracy (%) = (Qmeasured/Qset)100
Cycle Time = Filling Time + Transfer Time
7. Budget and Cost Analysis
The estimated cost breakdown is as follows:
Component Estimated Cost (₹)
Arduino uno 600
NEMA17 steppermotor and A4988 stepperdriver 1050
Relay module and solenoid valve 24 V 350
IR sensor module and power supply 12V,24V 1600
Conveyor materials and mechanical 2500
Wiring,connectors,terminal blocks 500
PCB prototyping,spare parts 1300
Total Estimated Cost 7900
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8. Risk Assessment
• Technical Risk: Possibility of hardware or software malfunction such as Arduino failure, IR sensor
misdetection, or motor driver fault. Regular testing and use of quality components reduce this risk.
• Operational Risk: Risk of conveyor jamming, bottle misalignment, or solenoid valve leakage during the
filling process. Proper mechanical design and preventive maintenance can minimize these issues.
• Electrical Risk: Involves dangers like short circuits, power surges, or incorrect wiring that may damage
components or cause safety hazards. Proper insulation and circuit protection help avoid this.
• Human Error Risk: Errors due to incorrect programming, calibration, or manual operation. Clear user
instructions and operator training are essential to reduce this risk.
• Environmental Risk: Effects of dust, humidity, or temperature changes that may affect electronic
components and sensors. Using protective enclosures and maintaining stable environmental conditions can
control this risk.
9. Benefits and Deliverables
Benefits
• Automation and Efficiency:The system automates the bottle filling process, reducing manual effort and
improving production speed.
• Accuracy and Consistency:Using sensors and programmed timing ensures each bottle is filled to the
correct level, minimizing wastage.
• Cost-Effective Design:Arduino-based automation provides industrial-like performance at a much lower
cost compared to PLC systems.
• Energy and Resource Savings:The system operates only when bottles are detected, conserving electricity
and reducing material loss.
• Scalability and Flexibility:The design can be easily modified for different bottle sizes, liquid types, or
filling volumes, making it adaptable for small industries.
Deliverables
• Working Prototype Model:A functional automatic bottle filling setup using Arduino, conveyor belt, IR
sensor, solenoid valve, and motor driver.
• Circuit Diagram and Block Diagram:Detailed electrical connections and overall system flow
representation.
• Arduino Program Code:Fully developed and tested code to control motor movement and bottle filling
sequence.
• Project Report Documentation:Complete report including introduction, working principle, circuit
explanation, and component details.
• Demonstration and Presentation:Practical demonstration of the prototype’s working and a brief
presentation summarizing project objectives and results.
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10. Evaluation and Testing Plan
The evaluation and testing plan for the Automatic Bottle Filling System using Arduino involves several stages to
ensure the system’s accuracy, reliability, and safety. Initially, each component such as the Arduino board, IR sensor,
solenoid valve, relay, and stepper motor is individually tested to verify its functionality and response to control
signals. After confirming proper operation of individual components, integration testing is carried out by
connecting all modules to form the complete system. This step ensures proper signal communication and
synchronization between the sensor, Arduino controller, and actuators. Functional testing is then performed to
check the automatic detection of bottles, conveyor stoppage, and precise filling operation. During this phase,
parameters such as filling time, valve response, and conveyor restart delay are monitored and fine-tuned.
Performance evaluation focuses on assessing filling accuracy, repeatability, power consumption, and overall
system efficiency. Finally, safety and reliability testing are conducted to verify that the system operates safely
under continuous use, with protection against short circuits or overloads. This systematic evaluation ensures that
the project meets its intended objectives of efficiency, accuracy, and automation reliability.
11. Future Scope
The future scope of the Automatic Bottle Filling System using Arduino includes upgrading the system with
advanced sensors like ultrasonic or flow sensors for higher accuracy. Integration of IoT or PLC technology can
enable remote monitoring and automation control. The setup can be expanded to include multiple filling stations
to increase production speed. Machine vision can be added for bottle detection and quality checking. With
improved mechanical design and components, the system can be adapted for large-scale use in industries such as
beverages and pharmaceuticals.
12. Conclusion
The Automatic Bottle Filling System using Arduino successfully demonstrates how automation can improve
efficiency, accuracy, and productivity in industrial operations. By using components such as the Arduino Uno, IR
sensor, solenoid valve, and stepper motor, the system automates the process of detecting, filling, and moving
bottles with minimal human intervention. The project highlights the potential of low-cost microcontroller-based
systems to replace manual operations and reduce errors. Overall, the system provides a simple, reliable, and
economical solution that can be further developed for large-scale industrial applications in the future.
13. References And Appendices
DIY Water Filling Machine using Flow Sensor & ArduinoAn automatic bottle filling system using Arduino can be
built by using sensors (like IR or ultrasonic) to detect bottles and liquid levels, an Arduino microcontroller for
control, and components like pumps, relays, motors, and displays to automate the filling process. Key references
include academic papers from journals like IRJET and IRJMETS, which detail the design and implementation of
such systems, while project-based sites like Hackster.io and ResearchGate provide practical examples and
schematics.
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