[Tutorial] : Automatic Bottle Filling & Capping System Using FAVORIOT Platform

This project focuses on automating the bottle filling and capping process using a combination of pneumatic systems, controllers, sensors, and IoT technology via FAVORIOT. The system aims to increase efficiency and reduce manual labor in the food and beverage industry.

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1. System Overview

The automated system will consist of:

• Bottle Detection: This uses sensors to detect the presence of a bottle.
• Liquid Filling: A pneumatic system controlled via a solenoid valve.
• Capping Mechanism: A stepper motor is used to secure bottle caps.
• Conveyor System: Moves bottles along the filling line.
• IoT Integration: Monitors real-time status and errors via FAVORIOT.

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2. Suggested Controllers & Sensors

2.1. Microcontroller/PLC Options

• Arduino Mega 2560 (Best for IoT & small-scale automation)
• ESP32 (For direct WiFi-based IoT integration)
• Siemens S7-1200 PLC (For industrial applications)
• Raspberry Pi (For advanced control with vision-based quality check)

2.2. Sensors & Actuators

Component	Purpose
Ultrasonic Sensor (HC-SR04)	Detects bottle presence
Infrared Sensor (TCRT5000)	Detects bottle position on the conveyor
Load Cell + HX711 Module	Measures the filled liquid weight
Solenoid Valve (12V DC)	Controls liquid dispensing
Stepper Motor (NEMA 17)	Tightens bottle caps
Relay Module	Controls pneumatic system & conveyor

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3. Hardware Setup

3.1. Wiring Connections

Bottle Detection (Ultrasonic Sensor)

• Trigger Pin → Arduino Digital Pin 7
• Echo Pin → Arduino Digital Pin 8

Filling System (Solenoid Valve via Relay)

• Relay IN Pin → Arduino Digital Pin 9
• Relay VCC & GND → Arduino 5V & GND
• Solenoid Valve → 12V DC Power Source

Capping Mechanism (Stepper Motor)

• Stepper Motor Driver (A4988) → Arduino Pins 10, 11, 12, 13
• Stepper Motor → Power Supply 12V

Conveyor Motor

• Motor Driver (L298N) → Arduino PWM Pins 5, 6
• Motor Power Supply → 12V DC

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4. Software Development

4.1. Arduino Code for Automation & IoT Integration

This code manages bottle detection, filling, capping, and data transmission to FAVORIOT.

4.1.1. Required Libraries

#include <WiFi.h>  // For IoT (ESP32)
#include <HTTPClient.h>
#include <AccelStepper.h> // For Stepper Motor


4.1.2. WiFi & FAVORIOT Setup

const char* ssid = "Your_WiFi";
const char* password = "Your_Password";
String apiKey = "your_favoriot_api_key";
String deviceId = "your_device_id";

void sendDataToFavoriot(int bottleCount, int errorStatus) {
    HTTPClient http;
    String serverPath = "https://apiv2.favoriot.com/v2/streams";
    
    String jsonData = "{\"device_developer_id\":\"" + deviceId + 
                      "\", \"data\": {\"bottles_filled\":\"" + String(bottleCount) + 
                      "\", \"error_status\":\"" + String(errorStatus) + "\"}}";

    http.begin(serverPath.c_str());
    http.addHeader("Content-Type", "application/json");
    http.addHeader("Apikey", apiKey);
    
    int httpResponseCode = http.POST(jsonData);
    http.end();
}


4.1.3. Ultrasonic Sensor for Bottle Detection

#define TRIG_PIN 7
#define ECHO_PIN 8

long duration;
int distance;

bool detectBottle() {
    digitalWrite(TRIG_PIN, LOW);
    delayMicroseconds(2);
    digitalWrite(TRIG_PIN, HIGH);
    delayMicroseconds(10);
    digitalWrite(TRIG_PIN, LOW);
    duration = pulseIn(ECHO_PIN, HIGH);
    distance = duration * 0.034 / 2;
    
    return (distance < 10); // Detect if bottle is within 10cm
}


4.1.4. Filling Process (Solenoid Valve Control)

#define SOLENOID_PIN 9

void fillBottle() {
    digitalWrite(SOLENOID_PIN, HIGH);
    delay(2000); // Fill for 2 seconds
    digitalWrite(SOLENOID_PIN, LOW);
}


4.1.5. Capping Process (Stepper Motor)

#define STEP_PIN 10
#define DIR_PIN 11

AccelStepper stepper(1, STEP_PIN, DIR_PIN);

void capBottle() {
    stepper.setMaxSpeed(500);
    stepper.setAcceleration(250);
    stepper.move(200);  // Rotate motor to tighten cap
    stepper.runToPosition();
}


4.1.6. Conveyor Control

#define CONVEYOR_PIN 5

void moveConveyor() {
    digitalWrite(CONVEYOR_PIN, HIGH);
    delay(1000); // Move bottle to next station
    digitalWrite(CONVEYOR_PIN, LOW);
}


4.1.7. Main Loop

void setup() {
    Serial.begin(115200);
    pinMode(TRIG_PIN, OUTPUT);
    pinMode(ECHO_PIN, INPUT);
    pinMode(SOLENOID_PIN, OUTPUT);
    pinMode(CONVEYOR_PIN, OUTPUT);

    WiFi.begin(ssid, password);
    while (WiFi.status() != WL_CONNECTED) {
        delay(1000);
        Serial.println("Connecting...");
    }
    Serial.println("Connected to WiFi");
}

void loop() {
    if (detectBottle()) {
        Serial.println("Bottle detected!");
        fillBottle();
        capBottle();
        moveConveyor();
        
        // Send data to FAVORIOT
        sendDataToFavoriot(1, 0);
    }
    delay(1000); // Wait before next detection
}


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5. IoT Dashboard & Remote Control Using FAVORIOT

5.1. Setting Up FAVORIOT Dashboard

1. Create a Device on FAVORIOT.
2. Define Parameters: Bottle count, filling status, errors.
3. Enable Alerts: Notify if liquid is low or if a bottle is missing.

5.2. Remote Control Features

• Start/stop the filling process remotely.
• Adjust fill time dynamically via IoT API.
• Monitor real-time status from a mobile app.

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6. Testing & Troubleshooting

Issue	Possible Cause	Solution
No bottle detection	Sensor misaligned	Adjust sensor position
Over/underfilling	Solenoid valve timing	Calibrate filling time
Capping failure	Stepper motor not aligned	Adjust torque settings
IoT connectivity issues	WiFi disconnects	Check API key & WiFi

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7. Future Enhancements

• Vision-Based Quality Control: Add a camera to detect defects.
• Predictive Maintenance: Monitor machine health via IoT.
• Energy Optimization: Optimize motor and pneumatic system usage.

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Conclusion

This project automates bottle filling and capping while providing real-time monitoring and remote control by integrating Arduino/PLC, sensors, stepper motors, and FAVORIOT IoT. This reduces manual labour, increases efficiency, and enables predictive maintenance in production lines.

References

• Favoriot Platform Registration (FREE and Paid)
• Favoriot Full Documentation (Official)
• Favoriot Github
• How-To Use Favoriot Platform Video Playlist

Disclaimer

This article provides a step-by-step guide. The source code may need adjustments to fit the final project design.