Nat. Volatiles & Essent.

Oils, 2021; 8(5): 3200-3220

Design of Automatic Food Grain and Powder

Packing Machine

1PrabhakaranS , 2Mohamed Rifayee Hussain Z , 3Sanjay S , 4Vasanthakumar S , 5Saravana kumar K ,

6Dineshkumar S

Dept. of Robotics and Automation Engg.

PSG College of Technology
Coimbatore, India
[email protected]

2Dept.of Robotics and Automation Engg.

PSG College of Technology
Coimbatore, India
[email protected]

3Dept.of Robotics and Automation Engg.

PSG College of Technology
Coimbatore, India
[email protected]

4Dept.of Robotics and Automation Engg.

PSG College of Technology
Coimbatore, India
[email protected]

5Dept.of Robotics and Automation Engg.

PSG College of Technology
Coimbatore, India
[email protected]

6Dept.of Robotics and Automation Engg.

PSG College of Technology
Coimbatore, India
[email protected]

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Abstract
This paper presents an automatic packing machine which packs both the food grains and powdered
spice. This functionality of this packing machine includes weighing the product, cover wrapping, filling
and date sealing. Many small-scale industries use manual packing since conventional machine is of high
cost and it has some other issues. This packing machine would solve the heating issues and also cost
effective.
Keywords – PLC, HMI, Weighing Hopper, Packing
I. INTRODUCTION
Packing machines are used throughout all the small-scale industries. This packing process includes
weighing the product, overwrapping, filling, date sealing, combining. Packing machine can be designed
for small packages or variable package size and some are adjustable to the package sizes. Manual packing
process can be slow and production rate slows down but automation line increases the production volume
and good quality of product. Generally Packaging machinery have some classifications which are
• Standard Type
• Custom Made
• Upgraded type
Standard type machinery is designed and developed by following certain procedures and criteria that
suits for specific type of application. Custom Made is a user defined machinery where customer provides
the requirement and then machine is customized according to their need and it is generally high-cost
machine and needs high maintenance. Upgraded type is more efficient packaging machinery where
standard type is used with some modifications in their design, features and functionality.
Some of the available machines use embedded systems for controlling purpose which may lead to
high heating issues that results in failure of some components. In such a case, frequent maintenance is
required and its cost also increases tremendously. The existing packing machines in the market will pack
either solid particles or powdered particles. Conventional powder packing machine has ribbon blender and
screw conveyor for stirring the powder and transferring the powder. There is a need for two separate
machines for packing both type of products and its maintenance cost also increases. Small industries cannot
afford two separate machines to pack different products.

Fig.1. Conventional Packing Machine

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Fig.1. shows the conventional packing machine. Conventional packing machine has the standard
procedure and methodology to pack the food grains and powder. In this paper, packing method of both the
food grains and powdered spices are integrated together. Sealing of the cover roll has separate mechanism.
Both for transparent cover and colored cover, it is able to seal the food grains with specified quantity and
length of the packet.
Next is the cost of conventional machine is too high in the market. There are only less numbers of
packing machine manufacturers which leads to high cost in the market. The cost for separate food grain
and powered spices packing machine is high. But if the packing method is integrated to a single machine,
the cost may be reduced to the half of its original cost.
RELATED WORK
II.
Few other works have been done in the relevant field.
Liu Cheng and Li Xiao gang [1] explained the come up with effective packaging strategies for a range
of industrial applications that may be executed utilizing quick, reasonably cost technology. When working
with industrial vision applications, which have severe issue limitations, a systems approach has been
explicitly chosen. As a result of this, there are two main components to the packing operation. In the first
case, morphological image processing procedures are used to create a geometric packing approach. As part
of an algorithmic packing method using prolog, this is employed. At the heuristic level, form ordering, and
shape orientation are addressed, both of which must be done before the geometric packer is implemented.
Problem limitations particular to a certain application are addressed via heuristic techniques.
Sadegh vosough and Amir vosough [2], It has been addressed about the importance of the idea of the
PLC and its application in the beginning, PLCs were meant to replace relay-based logic. PLCs were
programmed in "ladder logic," which closely resembled a diagram of relay logic, according to the report.
Because PLCs are designed for extreme circumstances (such as dust, moisture, heat, cold, etc.), they offer
a large number of input/output (I/O) options. The cost of a packaged PLC is inexpensive compared to the
cost of a custom-built controller design since PLC applications are generally highly customized.

Umesha. B. C and N. S. Sriram [3], According to this paper, a better packaging method will be
implemented, which will result in a smoother procedure and a better product. Many industries utilize screw
conveyors to move and/or elevate particles at a regulated rate. A wide range of industries utilize them for
a variety of bulk material applications. This paper will utilize PLC (Programmable Logic Controller)
programming to make the system run step-by-step.

Yundan Lu et al. [4], Filling systems have become increasingly popular as a result of the growth of the
beverage sector. As a result of its low automation and integration level, the relay control mechanism used
in traditional filling machines cannot keep up with the fast growth of automatic production. In recent years,
PLC control methods have increasingly replaced relay control methods due to their benefits in terms of
easy programming, robust anti-interference, and high operating dependability PLC-controlled automated
filling system hardware and software are created in this study, with specific attention paid to the injection
section's servo control system, which uses a servo motor-driven dosing pump, and the filling precision is
much enhanced.

Ganesh B.Shinde et al. [5] explains the initial stages in implementing a PLC-based auto-weighing
control system for the automation sector. For example, many engineers are striving to create an automated
system which operates extremely precisely, highly-effectively and within a short time period as a new
development in contemporary globalization The development of auto weighing systems is becoming
increasingly essential, especially due to the increasing demands for products and the shrinking supply of
skilled personnel in industry. Industry has been weighing tasks in recent years and rejecting them manually
if they are defective. As a result of automation (using load cells), defective tasks may now be rejected by
PLC, while accurate jobs can continue on the conveyor belt. Because the demand for the product is greater,

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the production pace should be higher in the industry. However, if we physically weigh the thing, it will
take more time to do so, and the total speed of manufacturing will be slowed down. The goal of this paper
is to build a PLC-based automation approach.

D.Kanimozhi et al. [6], As a part of the automation practices, this paper describes the use of a
Programmable Logic Controller (PLC). Using PLC software, the paper aims to develop and build a
compact, basic packaging system. The use of PLC technology is growing quickly, and it is proving to be a
useful tool in automating processes. Control and automation of the packing system is carried out using PLC
software. Consequently, the packing system was entirely automated. Apart from reducing product time and
increasing production rate, this system is more efficient than manual systems. A Programmable Logic
Controller (PLC) is used to automate a process in this study.
Gana V V and Dr. C Mallikarjuna [7], An automated packing process prototype is shown in this study
using a programmable logic controller (PLC). This has a direct influence on both the company's survival
and economic advantages due to the rapid development of packaging technology that relies on current
mechanization and automation. Small businesses can save money by using a low-cost automated packing
equipment. The pneumatic, mechanical, and electrical systems of this low-cost automated machine are
simple and easy to maintain. This paper presents a mechatronics system, which takes feedback from
sensors and accordingly sends signals to the parts.
III.METHODOLOGY
Methodology of the paper provides sequential step to be followed and each step deals with necessary
part of the packing machine. Fig.2. shows the flow chart of methodology.

Fig.2.Flow Chart

A. Problem Identification
In the small-scale industries, packing machine has some problems faced by the operators. There is a no
need for separate machines for powder and food grains packing. Frequent damage in heater used for sealing
the package due to voltage fluctuations. Heating issue has been major problem which results in failure of
some small components. As a result, frequent maintenance is needed to run the machine for long time.
B. Literature Survey
Many papers were studied to get clear working of packing machine. Methods used to pack the food
grains were analyzed. Different approaches used in packing machine were studied. PLC Programming and
logic used in packing machine were examined and studied.

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C. Target Specification
Some target specifications were specified after identifying the customer needs. Then the list of metrics
is created by considering problem statement and this metric is subjective.

D. Conceptual Design
After sorting out all the problems, various solutions have been framed and analyzed for the feasibility.
Here the problems with the existing packaging machine are divided into sub problems and each sub problem
is carefully taken into consideration and initially focused on critical sub problems which is the need of
single packaging machine for food grains and powder. After gathering this information, concepts were
generated and which end up in lots of ideas both feasible and some may unfeasible then eliminating the
less promising ideas & unfeasible ideas and identified the independent approaches to the problem. Now
Combining the idea/solutions of sub problems into single solution. And ensured that solution is focused too
much attention on combining the machine for food grains & powder while ignoring the overall
configuration and decided that this is the core of the problem and finalized to focus on this issue.
E. PLC Programming
Packing machine uses PLC as its main controller to operate the entire process. Certain sequence has to
be followed in the packing process. Each step in the sequence is controlled by different actuators and other
components. All the components are connected to the PLC. In order to maintain the sequential process,
Program need to be fed to the PLC. This program is in form of ladder logic where the logic of packing
process is specified. First of all, it is important to understand the logic and sequence of the process. PLC
Programming determine the process time and number of outlet packets. More attention should be given to
PLC Programming because it determines the efficiency of the machine.

F. Detailed Design
Considering design depend critically on design for commercial success and the design falls into any one
of these
• Ergonomic need
• Aesthetic need
Our aim is to mainly focus on ergonomic need as one of our sub problems is facing difficulty while
using HMI. Design of hopper and vibrator should meet as per the requirement of user. Considering the
food grain capacity, individual parts of packing machine must be designed and developed.

G. Stress Analysis
Static stress analysis is one of the important procedures to perform while designing all the mechanical
parts. Stress analysis gives us the better understanding of load acting on the mechanical part and
deformation while applying maximum load. This analysis helps to reduce the testing cost and time. In case
of more deformation of material, changes can be made in design before fabrication. Similarly, stress
analysis on packing machine needs to be done to ensure that design is will not be subjected to any
deformation under maximum load.

H. Testing
Once the design and stress analysis is completed, the packing machine is almost ready for next
procedure. Results from the stress analysis gives us a lot of details about design. Stress analysis on the
lower frame was made because it holds almost the entire machine. From the stress analysis result, entire
design is safe.

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IV. COMPONENT SELECTION

For the packing machine, there are many components used. Each component has its specific role in
packing machine. Main part of packing machine is the Programmable Logic controller and human machine
interface. Let’s discuss only the important parts of the packing machine.

A. PROGRAMMABLE LOGIC CONTROLLER(PLC)

Programmable logic controller is a type of microcontroller which uses to implement the logic, timing,
sequencing, counting and arithmetic operations to control the processes. It uses ladder logic to implement
the process. Because of its speed, stability and reliability, Delta’s DVP series programmable logic
controllers are utilized in a broad range of industrial automation equipment. In the packing machine Delta
DVP14SS2 PLC is used and it has 8 input ports and 6 output ports. It is a 32-bit PLC with programming
capacity of 8K steps.Fig.3 shows the Delta PLC used in packing machine.

Fig.3. Delta PLC

B. HUMAN MACHINE INTERFACE(HMI)

An HMI is a platform for interacting with automation technology. Delta's HMI solutions offer a number
of communication interfaces for rapid communication and control of a variety of equipment, systems, and
facilities. The touch is resistant and may be operated with gloves to avoid direct contact. It enables quick
system construction, reducing wiring and installation time, lowering operating expenses, and increasing
system efficiency by removing necessity time-consuming modifications and extra maintenance costs. In
the packing machine, Delta VS070HE-1 HMI is used which has a resolution of 800 x 480.It has 2 USB
ports and RS232 COM port. Fig.4 shows the Delta HMI used in packing machine.

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Fig.4. Delta HMI 7’’ display

C. RELAY
Relay is mechanical device which is used to protect and switch the circuit and for supporting high
power devices. All the circuits are equipped with relay in order to protect the circuit. The purpose of relay
is to avoid the excessive current flowing to the circuit to prevent the elements of the circuit. Similarly in
packing relay is used to prevent the damage of elements caused due to excessive current flow. Relay
MY4N DC24 is used in packing machine. Rated current is 7A and it is operable in DC. Fig.5 shows the
relay used in relay used in packing machine.

Fig.5. Relay

D. SOLID STATE RELAY

SSR is a compactly built contactless electronic switch device made up of an integrated circuit (IC) and
discrete components. SSRs can turn on or off the state of the electronic circuit very quickly, similar to the
function of traditional mechanical relays. Inside the SSR, there is no moveable mechanical part, and there
is no mechanical action during the switching operation. As a result, the Solid-State Relay is also referred
to as a "non-contact switch." The solid-state relay's amplification and drive function make it ideal for
driving high-power actuators, and it's more reliable than electromagnetic relays (EMR). Solid state relay
control switches utilize extremely little power, hence modest control currents can be employed to manage
high load currents. Between the input and output terminals, the solid-state relay employs robust and
dependable optoelectronic isolation technology. Fig.6 shows the SSR used in packing machine.

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Fig.6. Solid state relay

E. MINIATURE CIRCUIT BREAKER
When the network is in an unstable state, such as an overload or defective condition, an MCB is an
electrical switch that immediately shuts off an electrical circuit. When continuous current flows through
MCB, the bi-metallic strip gets heated and releases. Due to this circuit becomes open and current flow
stops to the circuit. In order to turn on the circuit, the MCB has to be turned on manually. In a short circuit,
however, when the current is rapidly raised, the nozzle linked to solenoid is electromechanically moved.
The latch mechanism is instantly released when the nozzle meets the trip lever, enabling the circuit breaker
contacts to open. Fig.7 shows the Miniature circuit breaker used in packing machine.

Fig.7. Miniature Circuit Breaker

F. TEMPERATURE CONTROLLER TC 533

Selected TC533 Temperature controller is of dual display controller, it had Thermocouple and RTD
input, it is available with both on/off and PID control action, Selected TC533 is a field selectable control
output by relay or SSR. Fig 4.9 shows the temperature controller TC 533 for Heating element. Fig.8 shows
the Temperature controller TC 533 used in heating element of sealing.

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Fig.8. Temperature controller TC 533

G. LOAD CELL
There are a number of measuring devices available in electronics that may be used for various purposes
based on their requirements. To measure weight, a single sensor called as a weight sensor or load cell is
utilized. This sensor is most often used in weighing systems, where it is utilized to decide weight for a
number of applications. Because weight sensors are known for their precision and consistency in giving
precise weight data, they may be used in the design of weighing systems. The operation of a loadcell is
dependent on converting a load into an electrical signal. Depending on the load and circuit used, the signal
might be a change in voltage, current, or frequency. This sensor detects the physical changes, which
includes force, weight, or pressure, and outputs a proportionate value. It converts a quantifiable and
standardized electrical signal from a force like as tension, compression, pressure, or torque. Fig.9 shows
the load cell which is used to weigh the food grains.

Fig.9. Load Cell

H. PROXIMITY SENSOR
A proximity sensor detects the existence of things in its near area without having to make direct touch
with them. This can be done by utilizing an electromagnetic field or an electromagnetic radiation beam
whose return signal varies in response to the presence of any item in the near area. Different types of
proximity sensors include capacitive proximity sensors and inductive proximity sensors, magnetic
proximity sensors which are required for different sorts of targets, such as plastic targets, metal targets,
and so on. The normal range of a proximity sensor is the range within which it can detect an object.
Because there are no mechanical parts and no physical contact between the sensor and the perceived
object, proximity sensors can last a long time and have a high level of reliability. Fig.10 shows the
proximity sensor used for industries

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Fig.10. Proximity Sensor

I. VIBRATOR AND FEEDER
Using a vibration-based feeder and a scale controlled by an automatic switch, food grains can be packed
in the same quantity every time, faster and safer. Vibration aids in the distribution of commodities within
packaging and other units, lowering packaging and transportation costs. Vibrators can also aid with
efficiency. As a result, industrial vibrator-based packaging solutions are adaptable to both major
businesses and small independent producers in terms of capacity and cost. Fig.11 shows the vibrator used
for weighing the food grains.

Fig.11.Vibrator and feeder

J. MOTOR
Electric motors are used to fill the packets with food grain and to pull the laminates off the rolls for
packaging. To enhance the manufacturing pace, it was determined to draw the laminates for 160 mm in
0.1 sec. To fill the appropriate quantity of food grain in the packets, a motor with a capacity of 0.5 HP is
required to operate the food grain at 1400 rpm. It was determined that a motor with a capacity of 0.5 HP
and a speed of 955 rpm is necessary to pull the laminates at the desired speed. A three-gear ratio was used
to boost the speed of the available motor. Fig.12 shows the motor used in packing machine.

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Fig.12.Motor
K. MOTOR DRIVE
Motor Drive is the essential component of packing machine. This component controls the input power
to the motor. The Motor and Motor drive together forms a Drive System. The motor drive is capable of
controlling the speed of the motor by changing the frequency of the motor. Actually, there are separate
drives for AC motor, DC motor and Servo Motor. Here the AC drive is used for this application. The
specification of this drive is chosen based on the requirement for application. Fig.13 shows the motor drive
used for controlling the motor in packing machine.

Fig.13.Motor Drive
L. SWITCHED MODE POWER SUPPLY
In an electronic power supply system, a switching regulator is utilized to correctly transfer electrical
power. It is a type of power supply unit that is often seen in computers and is used to regulate the voltage
to the specs of the computer. To change output voltage and current across different electrical topologies,
SMPS adjusts the foundations of typically lossless storage, such as capacitors and inductors. Switching
regulators in SMPS devices turn on and off the load current in order to maintain and regulate the voltage
output. SMPS’s, unlike linear power supplies, alternate between low energy loss, full-on and full-off
phases and spend far less time in high dissipation cycles, resulting in lower depletion strength. Fig.14
shows the SMPS used in packing machine.

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Fig.14.SMPS
M. PNEUMATIC CYLINDER
Pneumatic cylinders are the type of actuators which are used for low power applications. There are
various types of pneumatic cylinders depending on the operating pressure and some other parameters. For
packing machine miniature and compact cylinders are used for sealing the cover and weighing hopper
opening and closing. Date printing and Packet separations are also done with the help of these cylinders.
Miniature A51, A52 cylinder is used in the packing machine.Fig.15,16 shows the pneumatic cylinder used
for packing machine.

Fig.15.Miniature Pneumatic cylinder

Fig.16. Compact Pneumatic cylinder

V. DETAILED DESIGN

The design of packing machine has been done using the software Solidworks 2021. The dimension
of the machine has been formulated based on the requirement of clients. Each component in the packing
machine has been designed with the help of estimated dimensions. The parts of packing machine includes
hopper, vibrator, weighing hopper, vertical sealer and horizontal sealer. Each part has to be designed based

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on the estimated dimension. Along with all these parts external frame and some additional components
has to be added to achieve the complete structure of the packing machine.

A. HOPPER
The purpose of hopper is to load the food grains or powdered spices which is further fed to vibrator and
weighing hopper. The hopper is in shape of frustum. More quantity of food grains can be loaded to hopper
at once. Fig17. Shows the hopper for loading the food grains.

Fig.17.Hopper
B. VIBRATOR PLATE
The food grain from the hopper gets into vibrator Plate. An Electromagnet is attached to the bottom of
vibrator plate from which food grains enter into weighing hopper. Along with electromagnet Spring is
also attached to the bottom of vibrator plate. The purpose of vibrator is to pass the food grain to the
weighing hopper slowly to measure and pack the small quantities. Fig.18 shows the vibrator plate used
for loading food grain to weighing hopper.

Fig.18.Vibrator Plate with spring at base

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C. WEIGHING HOPPER
This is the most important part of packing machine where the food grains are weighed and packed
accordingly. The load cell is attached above to the weighing hopper. The required weight to be packed is
fed through HMI panel. Based on the weight given, load cell weighs the food grain and sends to the cover.
This weighing hopper design is based on the Four Bar linkage. Slight modification has been done in the
four-bar linkage where the frame length is varying. This mechanism is actually a Double rocker
mechanism where the crank and rocker oscillate to certain extent. A Pneumatic actuator is fitted to the
Connecting rod of weighing hopper which controls the opening and closing of the hopper. Fig.19 shows
the weighing hopper used to weigh the food grain using load cell.

Fig.19.Weighing Hopper

D. VERTICAL SEALING
Vertical Sealing is the initial step to done for plastic covers before putting the grains. Pneumatic
actuator is attached to this part which seals the cover vertically but it makes open in top and bottom. Also
heating element is attached to this part which heats the cover partially to seal the cover. There comes the
Horizontal sealing which completely seals all the sides and gives out the final packed food grains.
Pneumatic actuator is actuated based on the ladder logic given in PLC. Once the Vertical sealing and
Bottom of the cover sealing is done the weighed food grains will be put inside the cover. Fig.20 shows the
vertical sealer used for sealing the cover

Fig.20.Vertical Sealer

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E. HORIZONTAL SEALING
Once the Vertical sealing of cover is done, it is much more important to do horizontal sealing to get
fully packed food grains. Heating element is provided to seal the cover both upside and downside
openings. Similar to vertical sealing, horizontal sealing is also actuated by pneumatic actuators. Horizontal
sealing is done before putting the weighed food grains in the cover. After putting all the weighed food
grains in the cover, again horizontal sealing is to be done to seal the top opening and to get a complete
packets of food grain of particular weight. Along with horizontal sealer, a puller is attached just above to
it. Puller drags the cover from the cover frame roll and vertical sealing is done initially. Puller is also more
important component in sealing part. Fig.21 shows the horizontal sealer for sealing the top and bottom of
the cover.

Fig.21.Horizontal Sealer
F. HMI SCREEN
Human Machine Interface is an important component of this packing machine. Omron 7-inch Touch
screen panel is used. All the inputs to the machine are fed through this Touch screen HMI. Along with
HMI screen, Emergency stop button is also provided to turn it off in case of any emergency. Key lock is
given to avoid the unnecessary interruptions during the process which locks the settings and inputs given
to it. Fig.22 shows the HMI screen used for packing machine.

Fig.22.HMI screen

G. SUPPORTING FRAME
Two Frames are provided to support the components of the machine. One is upper frame and another
is the lower frame. Upper frame supports the hopper, vibrator and weighing hopper. Upper frame bears
more weight because the food grains are loaded into the hopper and food grains stays in hopper for long
time until the process starts. Lower frame supports the horizontal and vertical sealing components, Air
compressors for pneumatic actuators and HMI panel box. Also, Lower frame bears some weight which is

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almost equal to Upper frame. But these weights are permanent and it can never be reduced. Fig.23,24
shows the frame supporting the packing machine.

Fig.23.Upper frame

Fig.24.Lower frame
H. COVER ROLL FRAME
The plain cover is used for packing the food grains. This plain cover roll has to be fixed in some frame
and sealed to pack the food grains. Cover roll frame is freely rotatable where the plain cover can be dragged
for packing process. Initially, cover is vertically sealed and then bottom sealing is done. Now the cover is
ready to get the weighed food grains and after putting it top sealing is done. Finally, a packed food grain
is received. Cover roll frame provides a support to this entire process. Fig.25 shows the cover roll frame
used for packing frame.

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Fig.25.Cover Roll Frame

I. BAG FORMING RAIL
The purpose of bag forming rail is to fold the cover inwards and make it look like a packet. Before
vertical sealing, the cover should be folded properly to seal and load the weighed food grains. Wrong
folding may lead to spillage of food grains during transportation. So, this bag forming rail is the most
important part which folds the cover and prepares for sealing. Fig.26 shows the bag forming rail used for
sealing the cover.

Fig.26.Bag forming rail

J. FINAL DESIGN AND ASSEMBLY
The given above parts are the important parts of packing machine. After designing all the parts based
on the estimated dimensions, these parts have to be assembled to get a complete packing machine. Before
assembling all these parts, analysis on these frames have to be done and it will be explained in upcoming
chapters. This analysis will be very useful to study on stress and strain on the frame. All the designed parts
need to be mated based on the rough sketch. Motion constraints has to be done carefully for the necessary
parts. Also, there is a need for some freely movable parts which need to be specified during assembly. All
the motion constraints and fixed parts has to be specified in the assembly section. Thus, all the parts have

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been assembled and final design is achieved as per the problem requirement. Fig.27 shows the final design
and assembly.

Fig.27.Final Design of Packing machine

VI. STRESS ANALYSIS
Stress analysis is the visualization of load acting on the mechanical part. Deformation of
mechanical part at some of point of load can be calculated. A stress analysis can help to choose the best
design alternatives for a component or assembly. Autodesk fusion 360 helps to a great extend to the stress
and strain analysis and gives out lots of parameters. For the packing machine entire parts need not be
analyzed. Only part which is subjected to maximum load need to be analyzed and checked for safety
parameters. Here the lower frame holds the entire part of the packing machine and it is subjected to huge
load. Components on the lower frame alone weighs around 80 kg and material to be added in hopper
weighs around 20 -25 kg of food grains. Considering the maximum weight, total weight acting on the
lower frame is 105 kg. Using this weight, force acting on frame is calculated by formula F = m x g where
g is gravitational constant. After calculation, 1029 N force will be acting on the frame. Before analyzing
the stress on the frame, the material and measuring unit has to be specified. Then motion constraints have
to be specified because not all links of frame is subjected to load. Bottom face of the frame has no motion
constraints. After applying the uniformly distributed load of 1029 N on the upper face of frame, result will
be displayed. Maximum stress that frame can withstand is 10.53 MPa and it will deform in case if load is
applied more than allowable maximum load. Fig.28 shows the maximum allowable stress on the frame.

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Fig.28. Maximum allowable stress

Deformation of frame when maximum load is applied is also visualized. Maximum displacement is
0.05194 mm. Actually, yield stress for mild stress is 415 to 600 MPa. But for frame design analysis comes
around 10 MPa which is far less than the yield stress. Fig.29 shows the Displacement caused due to stress.

Fig.29. Displacement due to stress

Analysis results shows the safety factor is 15. A factor of safety of 5 to 8 is considered to be a safe to
operate. Since all the links are fixed in the frame, it has no degree of freedom. To conclude, the design is
safe to operate.

VII. PLC PROGRAMMING

The step by step working of the machine is controlled by PLC controller and the programming are done
using the ladder logics. Delta DVP14SS2 is used as the controller. It is common in every machine that all
the actions have to be frozen, the actions should be performed only if the emergency stop is disabled. As
pneumatics forms the major part of the actuations, the air pressure has to be monitored and maintained at
constant level to obtain the required functionalities Two sensors are used to monitor the status of the

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hopper level, one for low level and another for high level. If the materials are present above the low level
and upto the high level then only the indicator has to show that hopper is full, otherwise the operator has
to check whether material is present or not.ow level is detected in the hopper, the LLS_ON will send a
request to fill the hopper, Hopper_Fill_Request. Next step is to weigh the material for the set level and
send it to the packing portion. If the Function Block generates the output as weigh_pan_empty this will
trigger the output Ready_to_Weigh, this indicates that the pan box along with load cell is now ready for
the operation.The output of previous step triggers the output, Feed_gate_open, this in turn opens the gate
between the hopper and weighing hopper so that the material can flow towards the weighing portion.This
latest output is used to activate the output of Bulk_Feed_Active which will make the vibrator to transfer
material at a faster rate.Once the materials reach the weighing section, the load cell will be working under
the BULK_FEED FB, three outputs will be generated from the load cell outputs, overweight, underweight
and target weight. This is for the bulk weight, that is if the target weight is 2 kg, the bulk target will be 1.9
kg and the rest 100 g will be fed as fine feed in order to get more accuracy of packing and to avoid the
excess material going into a packet. If it is underweight, the bulk feed will be again activated to get the
required bulk target. If it is overweight the quantity will be adjusted in the fine feed part.Same as for Bulk
feed, the weight will be checked for fine feed also in the FINE_FEED function block and the output will
be used for the further control of input feed to get the target fine feed.If the eye sensor at the top detects
that the film roll is not there, then both the cover release motor and the cover puller motor will be activated
at the same time so that the cover can reach the sealing section.The eye mark sensor is not detected means,
the film has reached the sealing section and it is time to actuate the horizontal sealers and vertical sealer
so that the packet will be made before the material reaches the bag.Once the sealing is done, the materials
will be dispatched from the weighing hopper by actuating the cylinder present at the weighing hopper, so
that the material can reach the formed bag through the bag forming tube.

VIII. CONCLUSION
In this paper, the design of an automatic packing machine for small scale industries have been done.
Both the food grains and powdered spices can be packed using this machine. Many problems were
encountered in the packing process. Manual packing process requires a lot of time and energy to do it
perfectly. To solve this problem, many solutions were provided and came up with one final concept.
Compared to other commercial machines in the market, the designed product seems to be less cost and
more efficient. All the target specifications were added to the machine which meets the requirement of
customer. Final model of the machine was developed and all the motion constraints were specified. Static
stress analysis of the lower frame were done to ensure the safety of design and studied the strain on that
frame. PLC ladder logic were developed using ISP Soft software. All the design and analysis were
completely analyzed and studied.

IX.FUTURE SCOPE
Future work will be focusing on complete fabrication and testing on this packing machine. Field
trails will be done on various test cases. Improving the packing efficiency and fast production rate will be
intense work to be focused and developed in the future. Minimizing cost will be the essential work need
to be done and make it available for all the small-scale industry and even in grocery store in small size.
ACKNOWLEDGMENT
The authors received no financial support for the research, authorship, and/or for the publication of the
article.

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