Unlock the secret of hassle-free beer bottling with digital design

Glass Bottling Machine Glass Bottle Filler
Discover streamlined beer bottling solutions with iBottling's digital design technology for efficient production.

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Introduction of Beer Bottling

An updated beer bottling production line system is now available with a PLC-controlled automation that serves as an enormous benefit to any brewery. With electromechanical simulation design, the connection between software and management systems become much easier to create and manage. This results in more accurate filling processes which are simpler than ever before!

 (1) By utilizing a digital automated control system, beer production efficiency can be maximized. Not only will it slash costs associated with design and improve versatility to meet optimization needs on the manufacturing line without halting operations during development, but its implementation also reduces manual labor while allowing for straightforward expansion.

(2)We can make the working environment better by introducing digital technology into our plan. With this, we could revolutionize beer-filling systems to operate seamlessly in a virtual space – achieving maximum efficiency without suspending production or requiring any manual labor for design optimization!

The control unit for this automated beer filler is established on PLCs, plus with digital and PC technologies that automatically fill software to form an operational commissioning network paired with management systems along the line, allowing us to have total automation over beer-filling productions!

Automating the beer filling system allows us to improve operational efficiency and reduce manual labor and respond promptly and flexibly to our customers’ rising demands in this ever-evolving industry. With a more precise process that meets strict requirements, we will experience tremendous success within the beer production sector!


Overall design of the control system

2.1 General control requirements of beer automatic filling control system

The system powers on, the sensor registers if the hopper valve is closed, and it automatically regulates beer material weight before displaying it on the touch screen. Then, with pressure pushing it along, the beer enters its bottle for weighing with preset parameters to detect errors or miscalculations, which are immediately compensated. The Automatic Beer Bottling Control System includes a dosage weigher, solenoid valves, and a motor connected in series, as depicted in the block diagram below.


2.2 The beer production process is separated into several steps:

malting, dextrination, filtration, boiling, hopping, and more. Over time, however, the malting portion has become obsolete due to breweries eliminating their own plants entirely. Once every other step of this process is complete, the last stage begins – filling up bottles or cans with freshly brewed beer! This final phase can be automated to make it quicker and more efficient.


2.3 The filling control system is efficiently managed by a top-notch weighing instrument.

This advanced programmable controller extracts signals and controls the beer filling with utter accuracy while ensuring two separate stages of bulk feeding, allowing for speedier operations. To ensure weight accuracy during the process, testing must be conducted on the hopper immediately to prevent any potential errors caused by adhesion to its walls or other factors. As demonstrated in Figure 2, this method guarantees both effectiveness and precision!

Consequently, if the machine ceases to work correctly, this error must be addressed carefully to guarantee that the hopper is emptied. At system inception, one can set values such as whether a sensor-controlled hopper door is present; feed material quickly, moderately, or slowly under speed control parameters; assess steadiness at the end of each feeding signal and measure any discrepancies to rectify them on its subsequent cycle.

The Toledo B8520 weigher’s hopper mode powers the filling control system, as demonstrated in Figure 3. Via an IN port rising edge signal triggered by a sensor determining that the hopper door is closed, this weighing process kicks off with materials fed at a predetermined speed according to PLC programming and delayed for pre-designated time intervals. Then it’s incorporated weighing action performs its task before another sensor ascertains if gland signals are up to data expectations stipulated within the PLC program – ultimately bringing everything full circle through controller intervention and concluding this automated filling procedure.

beer bottling

The weighing instrument B8520 Toledo is a powerful electronic device capable of converting the signal from a weighing sensor into numerical display, storing, counting and printing weight data. The control unit of this system can input field measuring signals to compare with preset values before outputting them to a programmable controller which controls both coarse fill valves and fine-fill valves.


Digital Modeling of Automatic Beer Filling System

To accurately conform to the production process, we needed to digitally model the beer filling line. With SolidWorks software, a 1:1 scale digital replica of the line was built, and its layout was finalized on MCD software based on measurements taken from the live site (Figure 4).


Design of automatic beer filling system

4.1 Simulation of beer filling system

After the digital modeling process, we must virtually simulate the filling system utilizing MCD software. In this design of MCD, we analyze crucial sub-relationships through motion flow (illustrated in Figure 5) and set up corresponding sub-systems that follow our production cycle to its completion. Simulating beer production enables us to reach our desired goal: a fully automated line ready for operation.

To ensure the smooth running of your PLC’s software and digital simulation components, it is essential to link up its memory and interface with their respective control nodes (as displayed in Figure 6). This pairing will guarantee that MCD technology can precisely monitor all its parts via the PLC.

4.2 Control of beer filling system

Our highly specialized software optimizes the performance of your Toledo B520 with varying feed speeds and target values accessible through a PLC control system. With its swift monitoring feature on the touch screen display, you can instantly review all current data about your weighing process in one go! Additionally, you have complete visibility over each gate -fast speed, medium speed or low speed- plus bagging operations within seconds!

When programming the PLC, SM0.0 is activated once power is turned on and regulates a scan cycle that retrieves MBUS_CTRL to enable communication and signal “completion” via outputting power stream. It then configures parity mode and matches it with CH_Ready operands which contain states of eight consecutive channels stored in low byte bytes; if connection 0’s condition is “on,” bit 0 will correspond to “1”; similarly for connections 1–7. If the connection isn’t present, the corresponding bit should be assigned as “0”.


Configuration simulation of the control system

5.1 System configuration environment

Utilizing Configuration iBottling software, the control screen can be configured and simulated. Along with that, creating graphics for beer filling control system is effortless using the Kingview 6.60 development program, which provides a massive device support library including over 4,000 devices from more than 1,000 manufacturers; 

Scripting language processing; variable import/export & auto-generation options; visual interface operation panel, and accurate color display graphic designs featuring progressive colors & animation connection capabilities – all facilitated through an exclusive WebServer architecture! 

Furthermore, it supports publishing screens in real-time with access to historical data storage; OCX controls for new web publishing are also available! Lastly, it offers robust distributed alarm services and event process management abilities.


5.2 Establishment of configuration monitoring screen

Head to the File tab of your system and select ‘Save All’ in order to store all of your designs and programs. Afterward, a dialogue box labeled “Run System Setup” will appear on your screen. Then, navigate over to its Main Screen Configuration tab where you can choose ‘PC to PC Serial Communication’ as the primary display choice. As soon as you press OK – this selection is officially set up!

Streamline your workflow, save time and hassle with the simple click of a button! Easily located to either side of the project browser or simulation operation/debugging screen – all you have to do is press VIEW. By doing so, you are then granted access to its features (as seen in Figure 7). Now it’s easy as pie for anyone survey and adjust various settings such as conveyor belt speed. Make life easier now – unlock our incredibly powerful tool today!

Picture of John Lau.
John Lau.

John Lau, oversea project manager, an engineering graduate with expertise in optimizing beverage production equipment during his university studies, is now at the helm of global projects in the industry. Committed to educating clients on the benefits of customized equipment solutions that notably boost operational efficiency, Lau views this specialization in tailoring bottling machines as a key facet of his professional commitment.

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