Automatic Packaging Machine

FINAL YEAR PROJECT REPORT
Automatic Vertical Form Fill Seal (VFFS) Powder

Packaging Machine For Pharmaceutical Industry
THESIS SUBMITTED TOWARDS THE PARTIAL FULFILMENT OF THE REQUIREMENT OF THE

INDUS UNIVERSITY, FOR THE AWARD OF THE DEGREE OF DOCTOR OF PHILOSOPHY/MASTER
OF PHILOSOPHY IN ELECTRONICS TECHNOLOGY
SYED DAYYAN ASKARI (2102 – 2018)

ASIM MEHMOOD (2037 – 2018)
IBAD AHMED (1384 – 2018)
ZUBAIR AHMED (2101 – 2018)
FAIZAN AHMED (1949 – 2018)
Department of Electronics Engineering

Faculty of Engineering, Science & Technology (FEST)
Indus University, Karachi, Sindh, Pakistan
MARCH 2022
Automatic Vertical Form Fill Seal (VFFS) Powder
Packaging Machine For Pharmaceutical Industry
________________________________________________________________________________________
BY
Syed Dayyan Askari
(2102 – 2018)
Asim Mehmood
(2037 – 2018)
Ibad Ahmed
(1384 – 2018)
Zubair Ahmed
(2101 – 2018)
Faizan Ahmed
(1949 – 2018)
A project is to be submitted in the partial fulfillment of the

requirements of the Indus University for the degree of

Bachelor of Technology (Electronic) Engineering
I
CERTIFICATE
________________________________________________________________________________________
This project “Automatic Vertical Form Fill Seal (VFFS) Powder Packaging
Machine For Pharmaceutical Industry” presented by Syed Dayyan Askari,
Asim Mehmood, Ibad Ahmed, Zubair Ahmed, & Faizan Ahmed under the
direction of their project advisor’s & approved by the project examination
committee, has been presented to & accepted by the Department of Electronics
Engineering, Faculty of Engineering Science & Technology, Indus University,
in partial fulfillment of the requirements for Bachelor of Technology
(Electronics) Engineering.
_________________________________ _________________________________
Supervisor Name: Co-Supervisor Name:
Engr. Sheikh Zia Ur Rehman Engr. Taha Hassan
Designation: Lecturer/Co-Ordinator Designation: Lecturer
_________________________________
Internal Expert Name:
Designation: Lecturer
_________________________________ _________________________________
Chairperson Dean
Dr. Engr. Zahid Ali Prof. Dr. Engr. Ahmed Muddassir Khan
Department of Electronics Engineering Faculty of Engineering, Science &
Technology (FEST) Indus University, Karachi
Indus University, Karachi
II
DEDICATION
________________________________________________________________________________________
We, “Syed Dayyan Askari, Asim Mehmood, Ibad Ahmed, Zubair Ahmed, &
Faizan Ahmed”, the students of B-Tech (Electronics), that hereby declare the
Final Year Project (FYP-I) titled “Automatic Vertical Form Fill Seal (VFFS)
Powder Packaging Machine For Pharmaceutical Industry”, which is submitted
by us to the Department Of Electronics Engineering Technology, Indus
University Karachi. In partial fulfillment of requirement for the award of the
degree of (B-Tech Electronics), has not been previously formed the basis for the
award of any degree, diploma or other similar title or recognition.
The Author attests that permission has been obtained for the use of any copy
righted material appearing in the Project Report other than brief excerpts
requiring only proper acknowledgement in scholarly writing & all such use is
acknowledged.
III
ACKNOWLEDGEMENT
________________________________________________________________________________________
All praises & thanks to Al-Mighty “ALLAH”, the most merciful, the most
gracious, the source of knowledge & wisdom endowed to mankind, who
conferred us with the power of mind & capability to take this project to the
exciting ocean of knowledge. All respects are for our most beloved Holy Prophet
“HAZRAT MUHAMMAD (Peace Be Upon Him)”, whose personality will
always be source of guidance for humanity.
Acknowledgement is due to Faculty of Engineering Science & Technology for

support of this Project, a highly appreciated achievement for us in the
undergraduate level.
We wish to express our appreciation to our Supervisor (Engr. Sheikh Zia Ur

Rehman) who served as our major advisor. We would like to express our heartiest
gratitude for their keen guidance, sincere help & friendly manner which inspires
us to do well in the project & makes it a reality.
Many people, especially our classmates & team members itself, have made
valuable comment suggestions on this proposal which gave us an inspiration to
improve our project. We thank Supervisor (Engr. Sheikh Zia Ur Rehman), Co-
Supervisor (Engr. Taha Hassan) & Internal Expert ( )
& all the people for their help directly & indirectly to complete our project.
III
ABSTRACT
________________________________________________________________________________________
Many small-scale food production business owners & small & medium scale
grocery store owners do the process of weighing & packaging their product
manually. Small & Medium scale food production business owners who
particularly produce items like flour, spices, tea, etc has to do weighing, filling &
packaging process manually.
The sealing process is carried out with the help of candles. This process is very
time & effort consuming & thus it limits their production as well as their business.
It is observed that the cheapest machine which would automate this process of
weighing & packaging costs around Rs.1.25 lakhs & it is manufactured by ‘All
pack Engineers’. Automatic Weighing & Packaging which is priced at the rate
mentioned is not affordable for small scale & medium scale businesses. The aims
of this project is to develop such a machine which automatically weighs & packs
the food with the help of microcontroller & sensors. The idea is to manually place
the bag, then automatic weighing, filling & packaging is done.
The purpose of doing this project is to reduce human efforts & time consumption.
Decreasing machine cost is the major advantage of project. The machine design
is based on simple mechanisms & it can be installed easily. The speed of
packaging is increased thus resulting in more production & business. It will
eradicate the traditional packing & sealing method. This process will reduce the
number of paid workers.
IV
TABLE OF CONTENTS
________________________________________________________________________________________
CERTIFICATE I
DEDICATION II
ACKNOWLEDGEMENTS III
ABSTRACT IV
TABLE OF CONTENTS V
LIST OF TABLES VII
LIST OF FIGURES VIII
ABBREVIATIONS IX
CHAPTER 1 INTRODUCTION 1–3
1.1 PROJECT OVERVIEW 1
1.2 PROBLEM STATEMENT 2
1.3 AIM & OBJECTIVES 2
1.4 SCOPE OF THE PROJECT 3
CHAPTER 2 BACKGROUND & LITERATURE REVIEW 4–9
2.1 BACKGROUND 4
2.1.1 MANAGEMENT INFORMATION SYSTEM 4
2.2.1 NETSUITE RESOURCE MANAGEMENT SYSTEM 4
2.3.1 CLARIZEN RESOURCE MANAGEMENT SYSTEM 5
2.2 LITERATURE REVIEW 5
2.3 COMPARATIVE STUDY 8
CHAPTER 3 RESEARCH/SYSTEM DESIGN 10 – 41
3.1 SYSTEM METHODOLOGY 10
3.1.1 SOFTWARE REQUIREMENTS 10
3.1.2 HARDWARE REQUIREMENTS 26
V
3.1.3 SYSTEM CONSTRAINTS 35
3.1.4 EXTERNAL INTERFACE REQUIREMENTS 37
3.2 FUNCTIONAL REQUIREMENTS 37
3.2.1 USE CASES 38
3.2.2 ACTIVITY/FLOW CHART DIAGRAM 38
3.2.3 SEQUENCE DIAGRAM 39
3.3.4 ER-DIAGRAM 39
3.3 NON-FUNCTIONAL REQUIREMENTS 40
3.3.1 PERFORMANCE REQUIREMENTS 40
3.3.2 SECURITY REQUIREMENTS 41
CHAPTER 4 SYSTEM IMPLEMENTATION 42 – 49
4.1 SYSTEM DEVELOPMENT PROCESS 42
4.2 SIMULATION MODEL 43
4.3 SYSTEM FRAME WORK/SYSTEM ARCHITECTURE 44
4.4 MATHEMATICAL MODEL 44
4.5 ALGORITHMS/API/PACKAGES USED 45
4.6 DATABASE DESIGN & DEVELOPMENT 47
4.7 GUI DESIGN 48
CHAPTER 5 RESULTS & DISSCUSSION 50
5.1 RESULT 50
5.2 DISCUSSION 50
CHAPTER 6 CONCLUSION & FUTURE DIRECTIONS 51 – 52
6.1 CONCLUSION 51
6.2 FUTURE DIRECTIONS 52
REFERENCES 53
VI
LIST OF TABLES
________________________________________________________________________________________
TABLE 1 TABLE OF CONTENTS
TABLE 2 LIST OF TABLES
TABLE 3 LIST OF FIGURES
TABLE 2.3 TABLE OF COMPARATIVE STUDY
TABLE 3.1.2 TABLE OF COMPONENTS
TABLE 4.4 TABLE FOR ROUTE SHEET (SAMPLE)
TABLE 5.1 TABLE OF RESULT
VII
LIST OF FIGURES
________________________________________________________________________________________
FIGURE 3.1.3 3 CONSTRAINTS PROJECT
FIGURE 3.1.3 6 CONSTRAINTS PROJECT
FIGURE 3.2.1 USE CASES
FIGURE 3.2.2 ACTIVITY DIAGRAM
FIGURE 3.2.3 SEQUENCE DIAGRAM
FIGURE 3.2.4 ER DIAGRAM
FIGURE 4.1 SYSTEMS DEVELOPMENT LIFE CYCLE DIAGRAM
FIGURE 4.3 SYSTEM ARCHITECTURE DIAGRAM
FIGURE 4.5 ALGORITHMS DIAGRAM
FIGURE 4.6 DB DESIGN & DEVELOPMENT LIFE CYCLE DIAGRAM
FIGURE 4.7 MVC PATTERN IN GUI DESIGN DIAGRAM
FIGURE 6.1 CHART FIGURE FOR SYSTEM
VIII
ABBREVIATIONS
________________________________________________________________________________________
WIMP Windows, Icons, Menus, & Pointer
MIS Management Information System
API Application Programming Interface
GUI Graphical User Interface
DB Database
ADL Architecture Description Language
DBMS Data Base Management System
RPC Remote Procedural Call
TAPI Telephony Application Programming Interface
SOAP Simple Object Access Protocol
REST Representational State Transfer
MVC Model View Controller
SDLC System Development Life Cycle
JSON-RPC JavaScript Object Notation Remote Procedure Call
XML-RPC eXtensible Markup Language Remote Procedure Call
IX
CHAPTER 1
INTRODUCTION
1.1 Project Overview
A Vertical Form Fill Sealing (VFFS) machine is a type of automated assembly
line product packaging system, commonly used in the packaging industry for
food, & a wide variety of other products. Walter Zwoyer, the inventor of the
technology, patented his idea for the Vertical Form Fill Sealing (VFFS) machine
in 1936s, while working with the Henry Heide Candy Company. The machine
constructs plastic bags & stand-up pouches out of a flat roll of film, while
simultaneously filling the bags with product & sealing the filled bags. Both solids
& liquids can be bagged using this packaging system.
Types of Vertical Fill, Form & Seal (VFFS)

General speaking, as per the difference of form fill seal former, the types of VFFS
machine can be divided into two main categories.
a) Tube Type Vertical Form Fill Sealing (VFFS) Machine

b) Collar Type Vertical Form Fill Sealing (VFFS) Machine
a) Tube Type Vertical Form Fill Sealing (VFFS) Machine

Tube types of vertical form fill seal (VFFS) machine can only fill & seal the small
packaging volume of fin seal bag or side gusset bag.
b) Collar Type Vertical Form Fill Sealing (VFFS) Machine

Collar types of vertical form fill seal (VFFS) machine can only fill & seal the
large packaging volume of fin seal bag or side gusset bag.
As the difference of packaging contents & forming bag style, the types of VFFS
machine can be sub divided into below few kinds, such as:
1. Pillow Bag
2. 3 Side Sealed Bag
3. 4 Side Sealed Bag
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1.2 Problem Statement
Problem1 – Regulatory Failure:
Different jurisdictions have different regulatory & policy frameworks for
resource recovery & litter management. This broad regulatory failure results in
overlapping & duplication of costs as well as regulatory inconsistencies.
Problem2 – Negative Externalities:

When deciding whether to recycle packaging, individuals are likely to take into
account their private costs & benefits, however, these may be different from the
costs & benefits to society as a whole. Individual decisions to gram packaging
impose costs on 3rd parties, which are not taken into account by individuals when
making their decision.
Problem3 – Information Asymmetry:

There is a lack of coordination b/w local councils with regards to waste & gram
management. For e.g., there are inconsistencies in relation to curbside recycling
coverage & labelling. Information asymmetry causes confusion which acts as a
barrier to increased recycling.
Problem4 – Coordination, Transaction Costs and Free Riders:

Currently, it is impractical for the market to improve away from home recycling
infrastructure b/c there is difficulty in coordinating a large group of consumers &
businesses, there are high transaction costs associated with waste service
providers & there is potential for free riding.
1.3 Aim & Objectives

The major objectives of the project are:
• To design a machine which provides clean bag filling.
• To design a machine which is space saving.
• To design a machine which is easy to handle & runs on a simple mechanical
operation.
• To create a mechanism this would deliver the packed product.
• To create a machine which would be stable while operations.
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1.4 Scope of The Project
This machine can be used in many industries some of them are given below, but
scope of using this machine is not limited to this only.
• Small scale food production industries.
• Automatic Weighing & packaging machine for manufacturing industries.
• Used for the Pharmaceutical industries.
• Farmers can use it directly for packaging their agricultural products.
• Can be used in medium scale soap manufacturing industries.
Page 3
CHAPTER 2
BACKGROUND & LITERATURE REVIEW
2.1 Background
2.1.1 Management Information System

It is a computerized database of financial information organized & programmed
in such a way that it produces regular reports on operations for every level of
management in a company. It is usually also possible to obtain special reports
from the system easily. The main purpose of the MIS is to give managers
feedback about their own performance; top management can monitor the
company as a whole. Information displayed by the MIS typically shows "actual"
data over against "planned" results & results from a year before; thus, it measures
progress against goals. The MIS receives data from company units & functions.
Some of the data are collected automatically from computer-linked check-out
counters; others are keyed in at periodic intervals. Routine reports are
preprogrammed & run at intervals or on demand while others are obtained using
built-in query languages; display functions built into the system are used by
managers to check on status at desk side computers connected to the MIS by
networks. Many sophisticated systems also monitor & display the performance
of the companies.
2.1.2 NetSuite Resource Management System

We found a software related to one effective resource management is a priority
for all the professional services executives looking to optimize profit margins,
improve billable utilization, retain top talent & increase client satisfaction. With
NetSuite Resource Management, you can ensure that the right resources are
working on the right projects, based on real-time project timelines as the project
evolves. A comprehensive resource management system, NetSuite helps you
manage even the most complex project resource management requirements.
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2.1.3 Clarizen Resource Management System
Clarizen resource management solutions can help your business with real-time
visibility into available resources & current allocations. Identify & assign to the
right resources & ensure the projects are delivered on deadline. Clarizen are
enables you to:
• Handle requirements change

• Analyze resource demands
• Map personnel resources & responsibilities
• Use Clarizen's resource management systems to allocate resources to the right
projects more efficiently with fewer costs.
3 Literature Review
1. Mhalla, S. Collart Dutilleul & M. Benrejeb, titled as ‘Monitoring of

Packaging Machine Using Synchronized Fuzzy Petri Nets’, according to
authors The aim of this paper is the study & the design of a monitoring
module based on P-TPN for manufacturing job-shops with time constraints.
In such systems, operation times are included b/w a minimum & a maximum
value. The monitoring consists in a set of two collaborative PNs. The first is
used for modeling of normal behavior of the system by temporal spectrum
of the marking. The second model, SinFPN, corresponds to monitoring
activities. This paper proposes failures modeling & process monitoring for a
flexible manufacturing system with time constrains, using a P-TPNs &
SincFPN. A monitoring approach based on fuzzy model able to integrate
alarm signals & the moment of appearance of the external events in the
supervised system is presented. The aim of this original approach is to show
how the detection of the occurrence/persistence of the monitored external
events could make the supervision more efficient by performing an early
diagnosis. It is illustrated step by step on an example of a packaging machine.
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2. Yousef Moh. Abueejela & Abdul Hameed K. Belkasem, ‘Inspection,
Packaging & Packing Machine Development Based PLC’ this paper presents
an automated controlling system-based PLC that consists of two different
transporting conveyors; vertical & horizontal. The samples were placed on
the horizontal conveyor for transportation from loaded point to packaging
point. After the DC motor that drives the horizontal conveyor is energized,
the samples move along the conveyor before they reach an inspection sensor
that separates the two types of products & drop the chosen sample inside a
filling box. When the box is filled with the right number of samples, the
vertical conveyor picks & places these boxes inside vertical shelves. This
process is controlled using a PLC Mitsubishi FX2n-32MT. The experimental
results of the prototype were able to fully automate the system & improve
the time of inspection & packing. The results show that the machine was
done to inspect, package & pack24 boxes (96 samples) in one hour. In
addition, the results obtained show that the system able to decreases product
time, & increase product rate as compared with traditional manual system.
3. Rafael Couto Rodrigues de Oliveira, Claudio Garcia, titled ‘Simulator for a

packing & weighing system of granulated powders’, the development of a
simulator for a packing & weighing system (PWS) of granulated powder is
described. It employed system identification to obtain the deterministic part
of the model & stochastic processes to reproduce disturbances. It reproduces
the fluctuations in carton weight observed in real packing systems. Its final
use is to evaluate proposed improvements in the PWS, aiming at reducing
overweight & underweight. Its performance is satisfactory, as the
oscillations observed in the carton weights, due to powder density
variability, are close to reality as well as the monetary losses due to
overweight & underweight & the power spectral density graphs of the real
& simulated weights.
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4. Alhade A. Algitta, Mustafa S., Ibrahim F., Abdul ruof N. & Yousef M., titled
as ‘Automated Packaging Machine Using PLC, this paper presents FYP
prototype with the use of PLC in automation industry for packaging process.
The main idea of the project is to design & fabricate a small & simple
conveyor belt system, & automate the process for packaging small cubic
pieces (2×1.4×1) cm3 of wood into small paper box (3×2×3) cm3. Inductive
sensor & photoelectric sensor were used to provide the information to the
controller. Electrical DC motors used as output actuators for the system to
move the conveyor belts after get the orders from the control system. PLC
Mitsubishi FX2n- 32MT was used to control & automate the system by
ladder logic diagram software. The experimental result of the prototype was
able to fully automate the packaging system. This result shows that the
machine was done to package 21 boxes in 1 min. In addition, the results
obtained show that the system able to decreases product time, & increase
product rate as compared with traditional manual system.
5. Dirk Schaefer & Wai M. Cheung, ‘Smart Packaging: Opportunities &

Challenges’, the authors said that the global market for smart packaging is
expected to reach $26.7bn by 2024. Smart packaging refers to packaging
systems with embedded sensor technology used with food, pharmaceutical,
& many other types of products. It is used to extend shelf life, monitor
freshness, display information on quality, & improve product & customer
safety. In addition, smart packaging offers new business opportunities based
on digitization & thus fits into the broader realm of Industry 4.0. This
development, the need of agile & reconfigurable production systems
emerged to cope with various products & product families. To design &
optimize production systems as well as to choose the optimal product
matches, product analysis methods are needed. Indeed, most of the known
methods aim to analyze a product or one product family on the physical
Page 7
level. Different product families, however, may differ largely in terms. E
known methods aim to analyze a product or one product family on the
physical level. Different product families, however, may differ largely in
terms of the number & nature of components. This fact impedes an efficient
comparison & choice of appropriate product family combinations for the
production system. A new methodology is proposed to analyze existing
products in view of their functional & physical architecture.
2.3 Comparative Study

Horizontal form, fill & seal (HFFS) technology was developed as a high-speed
alternative to vertical form, fill & seal (VFFS) machines. Customers determined
in the early 1990s that while VFFS machines performed well in high-speed food
& small package (10l lb. & under) applications, their basic design & operating
principles didn’t lend them to effective bagging & longevity in industrial bagging
applications. The VFFS machine didn’t meet reliability requirements.
Since its introduction in 1994, horizontal form, fill & seal technology has replaced
100s of poor performing FFS machines. The success of HFFS technology is based
on 3 primary design differences.
• HFFS machines crease a bag away from the fill opening, eliminating
interaction of product to the bag forming process.
• HFFS machines run large bags 30%+ faster than VFFS machines.
• HFFS machines have fewer critical moving parts in the fill area, improving up
time & longevity with dirty, dusty, & corrosive products.
Page 8
Table 2.3: Table of Comparative Study
Page 9
CHAPTER 3
RESEARCH/SYSTEM DESIGN
3.1 Research/System Methodology
Phase-I (Studying)
Studying about the previous related research for this technology & primarily
focused on understanding & modeling a particular model.
Phase-II (Designing)
Designing the project model, Sourcing the components which we are used in this
project & write initial programing. Making rough sketch of the model. Making of
Computer-Aided Design (CAD) Model. Collecting the required components after
making the list. Programming on Arduino Mega.
Phase-III (Implementation)
Will do the hardware implementation of the design model. Assembling all the
components which we are use in this project.
Stage 1
a) Making of the uppermost hopper which will be used for storage.
b) Opening closing mechanism for the hopper.
Stage 2
a) A weighing utensil to hold the stuff to be measured is attached to the load cell.
b) Another mechanism that will put the measured stuff into the funnel. Attaching
funnel below the weighing utensil so that material directly falls in its.
3.1.1 Software Requirements
Arduino Programming Language
The programming of an Arduino Mega 2560 can be done with the help of an IDE
Arduino Software, & it supports C programming language. Here the sketch is the
code in the software which is burned within the software & then moved to the
Arduino board using a USB cable. An Arduino mega board includes a boot loader
which eliminates an external burner utilization to burn the program code into the
Arduino board. Here, the communication of boot loader can be done using an
STK500 protocol.
Page 10
All the user has to do to start compiling their sketch & press a button. If there are
any errors in the Arduino code a warning message will flag up prompting the user
to make changes. Most new users often experience difficulty with compiling
because of Arduino string syntax requirements. If you make any mistake in your
program when using Arduino, the code won’t be compile & then you’ll be met
with an error message.
Coding For Arduino Mega 2560
#include <Servo.h>
#include "HX711.h"
#include <Keypad.h>
#include <Wire.h>
#include <LiquidCrystal_I2C.h>
LiquidCrystal_I2C lcd(0x27, 2, 1, 0, 4, 5, 6, 7, 3, POSITIVE);
HX711 scale;
Servo myservo;
Servo myservo2;
const int LOADCELL_DOUT_PIN = 2;

const int LOADCELL_SCK_PIN = 3;
const byte ROWS = 4;

const byte COLS = 4;
char hexaKeys[ROWS][COLS] = {
{'1', '2', '3', 'A'},
{'4', '5', '6', 'B'},
{'7', '8', '9', 'C'},
{'*', '0', '#', 'D'}
};
byte rowPins[ROWS] = {29, 28, 27, 26};
byte colPins[COLS] = {25, 24, 23, 22};
Keypad customKeypad = Keypad( makeKeymap(hexaKeys), rowPins, colPins, ROWS, COLS);
////////////////////////////////////////////////////
int count = 0;
int pos = 0;
int set_weight = 20;
int set_time = 3000;
float packet_weight = 0;
int pos1 = 10;
String state = "STOP";
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int m_hopper_1 = 32;
int m_hopper_2 = 33;
int m_hopper_pwm = 7; //////// Blue
/////////////////////
int m_heater_1 = 30;
int m_heater_2 = 31;
/////////////////////
int heater = 12;
/////////////////////
int m_roller_f1 = 8;
int m_roller_f2 = 9;
int m_roller_fpwm = 5;
int m_roller_r1 = 10;
int m_roller_r2 = 11;
int m_roller_rpwm = 6;
int fb = 53;
void setup() {
Serial.begin(9600);
lcd.begin(20, 4);
Serial.println(" ");
Serial.println("SYSTEM........");
pinMode(m_hopper_1, OUTPUT);
pinMode(m_hopper_2, OUTPUT);
pinMode(m_hopper_pwm, OUTPUT);
////////////////////////////
pinMode(m_heater_1, OUTPUT);
pinMode(m_heater_2, OUTPUT);
////////////////////////////
pinMode(heater, OUTPUT);
/////////////////////////////////
pinMode(m_roller_f1, OUTPUT);
pinMode(m_roller_f2, OUTPUT);
pinMode(m_roller_fpwm, OUTPUT);
/////////////////////////////////
pinMode(m_roller_r1, OUTPUT);
pinMode(m_roller_r2, OUTPUT);
pinMode(m_roller_rpwm, OUTPUT);
pinMode(fb, INPUT_PULLUP);
myservo.attach(4);
myservo.write(0);
myservo.detach();
myservo2.attach(13);
myservo2.write(10);
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/////////////////////////////
int_loadcell ();
scale.power_up();
//////////////////////////////////
while (digitalRead(fb) == LOW) {
digitalWrite(m_heater_1, LOW);
digitalWrite(m_heater_2, HIGH);
}
/////////////////////////////////
lcd.clear();
lcd.setCursor(2, 0);
lcd.print("SMART - SEALING");
lcd.print("* MACHINE *");
lcd.print("Indus Uni, KHI");
delay(5000);
lcd.clear();
lcd.print("Starting Machine...");
/////////////////////////////////////////////
/////////////////////////////////////////////
delay(3000);
lcd.clear();
home_page ();
void loop() {
char key = customKeypad.getKey();
if (key) {
// Serial.println(key);
if (key == 'C') {
prg_page ();
}
if (key == 'A') {
machine_run ();
}
}
}
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void machine_run () {
lcd.clear();
lcd.print("Counter:");
//////////////////////
lcd.print("M/C Status:");
//////////////////////
lcd.print("S.W:");
lcd.print("P.W:");
///////////////////////
lcd.print("A:RUN B:STOP C:PRG");
Serial.println("Machine Start...");
state = "ON";
bool key = true;
////////////////////////////////////
while (key) {
lcd.print(count);
/////////////////////
lcd.print(state);
/////////////////////
lcd.print(set_weight);
//////////////////////
lcd.print(packet_weight);
//////////////// PACKET WEIGHT ////////////////////////

bool w1 = true;
Serial.println("--------**************---NEW PACKET---**************----------");
for (pos1 = 10; pos1 <= 140; pos1 += 1) {
myservo2.write(pos1);
Serial.println(pos1);
delay(5);
}
while (w1) {
Serial.print("Current Weight: ");
Serial.println(packet_weight);
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digitalWrite(m_hopper_1, LOW);
digitalWrite(m_hopper_2, HIGH);
analogWrite(m_hopper_pwm, 70);
loadcell ();
/////////////////////////////////////////////////////
char data = customKeypad.getKey();
if (data == 'B') {
Serial.println("Machine Stop...");
for (pos1 = 140; pos1 >= 10; pos1 -= 1) {
delay(5);
}
key = false;
w1 = false;
state = "OFF";
lcd.print(state);
goto label;
}
if (packet_weight >= set_weight) {
for (pos1 = 140; pos1 >= 10; pos1 -= 1) {
delay(5);
}
Serial.println("Weight Complete....");
w1 = false;
delay(2000);
}
delay(200);
}
////////////////// Weighing /////////////////////
////////////// SERVO TURN /////////////////////

Serial.println("TURNING SERVO");
servo1 ();
delay(1000);
///////////// HEATER CLOSE ////////////////////
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bool dns = true;
int counti = 0;
///////////////////////////////////////////////
Serial.println("HEATER CLOSING.....");
while (dns) {
Serial.println(counti);
if (data == 'B') {
key = false;
w1 = false;
dns = false;
state = "OFF";
lcd.print(state);
goto label;
}
if (counti >= 1200) {
dns = false;
counti = 0;
}
counti++;
}
delay(2000);
///////////// HEATING BAG ///////////////////////
Serial.println("---*** HEATING PACKET ***---");
digitalWrite(heater, HIGH);
delay(set_time);
digitalWrite(heater, LOW);
delay(2000);
///////////// HEATER OPEN /////////////////////
Serial.println("HEATER OPENING.....");
}
delay(2000);
///////////// ROLLERS DOWN /////////////////////
Serial.println("ROLLERS TURNING DOWN....");
Page 16
digitalWrite(m_roller_f1, HIGH);
digitalWrite(m_roller_f2, LOW);
analogWrite(m_roller_fpwm, 100);
digitalWrite(m_roller_r1, LOW);
digitalWrite(m_roller_r2, HIGH);
analogWrite(m_roller_rpwm, 100);
delay(600);
/////////////////////////////////////////////////
/////////////// AGAIN SELAING ////////////////
///////////// HEATER CLOSE ////////////////////
Serial.println("HEATER CLOSING.....");
dns = true;
while (dns) {
Serial.println(counti);
if (data == 'B') {
key = false;
w1 = false;
dns = false;
state = "OFF";
lcd.print(state);
goto label;
}
if (counti >= 1200) {
dns = false;
counti = 0;
}
counti++;
}
delay(2000);
///////////// HEATING BAG ///////////////////////
Serial.println("---*** HEATING PACKET ***---");
Page 17
delay(set_time);
delay(2000);
///////////// HEATER OPEN /////////////////////
Serial.println("HEATER OPENING.....");
}
delay(2000);
///////////// ROLLERS DOWN /////////////////////
if (set_weight == 20) {
delay(900);
}
delay(1000);
}
Page 18
delay(1100);
}
delay(1200);
}

if (data == 'B') {
key = false;
state = "OFF";
lcd.print(state);
}
count++;
delay(1000);
}
label:
Serial.println("EXIT.....");
}
Page 19
void prg_page () {
Serial.println("PRG PAGE....");
char data = '0';

bool key = true;
lcd.clear();
lcd.print("A: Set Packet Weight");
lcd.print("B: Set Sealing Time");
lcd.print("C: Load P.V Bag");
lcd.print("D: Manual Seal");
while (key) {
data = customKeypad.getKey();
if (data == 'A') {
lcd.clear();
lcd.print("1: 20Gms / Unit");
while (key) {
if (data == '1') {
lcd.clear();
lcd.print("WEIGHT SELECTED:");
lcd.print("20Gms / Unit");
set_weight = 20;
delay(3000);
key = false;
home_page ();
}
if (data == '2') {
lcd.clear();
Page 20
set_weight = 30;
delay(3000);
key = false;
home_page ();
}
if (data == '3') {
lcd.clear();
set_weight = 40;
delay(3000);
key = false;
home_page ();
}
if (data == '4') {
lcd.clear();
set_weight = 50;
delay(3000);
key = false;
home_page ();
}
if (data == '5') {
lcd.clear();
lcd.print("OPEN SEALER");
}
key = false;
home_page ();
}
}
}
if (data == 'B') {
lcd.clear();
Page 21
lcd.print("1: 3.0Sec / Unit");
while (key) {
if (data == '1') {
lcd.clear();
lcd.print("TIME SELECTED:");
lcd.print("3.0Sec / Unit");
set_time = 3000;
delay(3000);
key = false;
home_page ();
}
if (data == '2') {
lcd.clear();
set_time = 3500;
delay(3000);
key = false;
home_page ();
}
if (data == '3') {
lcd.clear();
set_time = 4000;
delay(3000);
key = false;
home_page ();
}
if (data == '4') {
lcd.clear();
Page 22
set_time = 4500;
delay(3000);
key = false;
home_page ();
}
}
}
if (data == 'C') {
load_pv ();
key = false;
}
if (data == 'D') {
seal_manu ();
key = false;
}
}
}
void home_page () {
Serial.println("HOME PAGE....");
loadcell ();
lcd.clear();
lcd.print("Counter:");
lcd.print(count);
//////////////////////
lcd.print("M/C Status:");
lcd.print(state);
//////////////////////
lcd.print("S.W:");
lcd.print(set_weight);
lcd.print("P.W:");
///////////////////////
Page 23
lcd.print("A:RUN B:STOP C:PRG");
delay(1000);
}
void load_pv () {
lcd.clear();
lcd.print("Loading PV Film");
lcd.print("Processing....");
/////////////////////////////////
delay(10000);
///////////////////////////////////
home_page ();
}
void seal_manu () {
lcd.clear();
lcd.print("MANUAL SEALING");
lcd.print("Sealing....");
delay(3500);
home_page ();
}
///////////////////////////// MC RUN UDFs //////////////////////////////
Page 24
void servo1 () {
myservo.attach(4);
for (pos = 0; pos <= 65; pos += 1) {
myservo.write(pos);
delay(20);
}
delay(1500);
///////////////////////////////////////
for (pos = 65; pos >= 0; pos -= 1) {
myservo.write(pos);
delay(20);
}
myservo.detach();
}
void loadcell () {
// scale.power_up();
// Serial.print("one reading:\t");
//Serial.print(scale.get_units(), 1);
//Serial.print("\t| average:\t");
packet_weight = scale.get_units(10);
// Serial.println(packet_weight);
//scale.power_down();
//delay(2000);
}
void int_loadcell () {
lcd.clear();
lcd.print("SYSTEM INT....");
scale.begin(LOADCELL_DOUT_PIN, LOADCELL_SCK_PIN);
Serial.println("Before setting up the scale:");
Serial.print("read: \t\t");
Serial.println(scale.read());
Serial.print("read average: \t\t");
Serial.println(scale.read_average(20));
Serial.print("get value: \t\t");
Serial.println(scale.get_value(5));
Serial.print("get units: \t\t");
Serial.println(scale.get_units(5), 1);
scale.set_scale(2280.f);
scale.tare();
Serial.println("After setting up the scale:");
Serial.print("read: \t\t");
Serial.println(scale.read());
Serial.print("read average: \t\t");
Serial.println(scale.read_average(20));
Page 25
Serial.print("get value: \t\t");
Serial.println(scale.get_value(5));
Serial.print("get units: \t\t");
Serial.println(scale.get_units(5), 1);
Serial.println("Readings:");
lcd.print("SYSTEM RDY....");
}
3.1.2 Hardware Requirement

S.NO. COMPONENTS QUANTITY
1 Hooper 01
2 10mm Screw Rod & Chamber 01
3 Hopper Gate 01
4 5V DC Servo Motor 02
5 1Kg Load Cell HX711 01
6 Funnel Tube 01
7 PVC Shrink Film Roll 01
8 Rollers With Pin Rollers 02
9 24V DC Gear Motors 04
10 Sealer 220V AC / 2A 01
11 Linear Actuator 01
12 PSU 220V AC – 24V DC (SMPS) 01
13 Arduino Mega 2560 01
14 LCD 20 x 4 I2C Module 01
15 Panel Mount Switch 01
16 Membrane/DOT Matrix Keypad 4 x 4 01
17 12/24V – 5V 5A DC - DC Buck Convertor 01
18 L298D H Bridge Motor Driver Module 02
19 SPDT Relay Module 01
20 Wooden Body 01
Table 3.1.2: Table of Components
Page 26
1. Hooper
It can be customized as per required needs of valuable patrons. The offered range
is widely appreciated by the esteemed customers for unmatchable characteristics.
This product is manufactured under the guidance of experts & in accordance with
industry defined parameters. The offered range is well tested on various
parameters in order to deliver flawless range to the end user. This product is
dispatched in perfect packaging material for safe transportation.
2. 10mm Screw Rod & Chamber

It’s a stainless-steel screw rod to revolved in chamber the oil squeezed out from
the seeds & turns out through holes. This is a main mechanism of machine
without screw rod & chamber the powder is not obtained due to the airtight in the
hopper when it is processing.
3. Hopper Gate
A hopper gate opening/closing mechanism for use in a combination weigher
includes a servo motor for generating a driving force for opening & closing the
hopper gate & for opening & closing the hopper gate based on the driving force
applied by the servo motor wherein the inhibits the hopper gate from being
opened in a position at which the hopper gate is closed.
Page 27
4. 5V DC Servo Motor
DC servo motors are normally used as prime movers in computers, numerically
controlled machinery applications where starts & stops are made quickly &
accurately. Servo motors have lightweight, low-inertia armatures that respond
quickly to excitation-voltage changes.
5. 1kg Load Cell HX711

To measure weight & load of any object we use strain gauges but problem with
using standalone strain gauge is that they are fragile & are easily bent & break if
not used in proper enclosure. This load cell made up of aluminium alloy can
measure up to 1kg load & outputs in the form of electrical signals proportionally.
This sensor will use a HX711 Analog to Digital signal converter, it is easy to use
with driving voltage 5-10V & produce the output voltage as per the force changes
over it, to read & send the data to the microcontroller board you are using as the
analog signal from the load cell is too small to be read easily. They are used in
Platform scales, electronic weighing machines, belt scales, etc.
Page 28
6. Funnel Tube
The stainless-steel funnel can be used to pour & transfer free-flowing powders,
liquids & slightly viscous media easily. An air channel on the discharge tube
ensures a complete, unobstructed flow. Depending on the diameter, this pouring
aid is suitable for dispensing applications, from small amounts in laboratories to
large quantities in industry. Larger versions of the funnel feature a handle to
ensure easy handling.
7. PVC Shrink Film

A type of shrink wrap used for a variety of applications. The PVC stands for
Polyvinyl chloride. PVC is the 3rd most-produced plastic in the world. PVC
shrink wrap was the most commonly used shrink film until replaced several years
ago by polyolefin (POF) shrink wrap.
8. Rollers With Pin Rollers

PU rollers are widely used in mechanical manufacturing, packaging & print
industry, glasses manufacturing, wooden & building materials industry, paper
industry & some special area where need the PU rollers. Driven wheels are widely
used in automatic vehicle & running parts of assembly line. Our wheels are made
of high-quality imported PU materials & you can choose materials MDI, NDI.
Page 29
9. 24V DC Gear Motors
A gear motor is an all-in-one combination of a motor and gearbox. The addition
of a gear head to a motor reduces the speed while increasing the torque output.
The most important parameters in regards to gear motors are speed (rpm), torque
(lb. – in) & efficiency (%).
10.Sealer 220V AC / 2A
It a simple contact-type working mechanism wherein a nichrome heating element
strip is heated electrically by means of a transformer. This heat is then imparted
to the plastic bag, which along with the pressure applied by the operator's hand
fuses the open end to form a airtight seal. Operators can control the heating time
by adjusting a knob provided on the front face. The PFS-200 plastic bag sealer
has a sealing length 8"/200 mm & sealing width 2 mm.
Page 30
11.Linear Actuator
An electric linear actuator is a device that converts an AC or DC electric motor’s
rotational motion into linear motion. The linear motion is created by rotating the
actuator’s screw via the motor. The screw turns either clockwise/anticounter
clockwise, & this causes the shaft to move in a line, up & down, creating the
push/pull effect for the load.
12.PSU 220V AC – 24V DC (SMPS)

The main job of an AC/DC power supply is to transform the AC voltage into a
DC voltage, which can be used to power different electrical devices. AC voltage
is used to transport electric power all across the electric grid, from generators to
end users. A 24V Power supply can change AC – DC. In addition to converting
the AC – DC power, the voltage level can be adjusted at the same time. Some
devices need DC but only have access to the AC coming from the wall.
13.Arduino Mega 2560

The Arduino Mega 2560 is a microcontroller board based on the ATmega2560.
It has 54 digital input/output pins (of which 15 can be used as PWM outputs), 16
analog inputs, 4 UARTs (hardware serial ports), a 16 MHz crystal oscillator, a
USB connection, a power jack, an ICSP header, and a reset button.
Page 31
14.LCD 20 x 4 I2C Module
It is a 20x4 Arduino compatible LCD display module with high speed I2C
interface. It is able to display 20x4 characters on 2 lines, white characters on blue
background. Generally, it will run out of Arduino pin resource. It needs 6 digital
pins & 2 power pins for an LCD display. If you want to build a robot project, it
will be a problem with Arduino UNO & LCD display. This LCD display module
is designed for Arduino microcontroller. It is using I2C communication interface,
with this I2C interface, only 2 lines I2C are required to display the information
on any Arduino based projects. It will save at least 4 digital / analog pins on
Arduino. All connector is standard breadboard type. You can connect it with
jumper wire directly.
15.Panel Mount Switch

Panel mount switches are designed to sit outside an enclosure. Panel mount
switches come in all sorts of termination styles: through-hole, surface mount or
solder lugs.
Page 32
16.Membrane/DOT Matrix Keypad 4 x 4
4x4 keypad modules are available in different sizes & shapes. But they all have
same pin configuration. It is easy to make 4x4 keypad by arranging 16 buttons in
matrix formation by yourself. A 4x4 keypad will have 8 terminals. In them 4 rows
of matrix & 4 columns of matrix. These 8 pins are driven out from 16 buttons
present in the module. Those 16 alphanumeric digits on the module surface are
the 16 buttons arranged in matrix formation.
17.12/24V – 5V 5A DC – DC Buck Convertor Module

This DC-DC converter converts a voltage from 12V – 24V DC to 5V DC 5A
(25W). This module is particularly useful for use in a vehicle delivering a basic
voltage of 12V. The converter is integrated in a waterproof aluminum shell and
has a 5.5/2.1mm jack connector at the output.
Page 33
18.L298N H Bridge Motor Driver Module
The L298N is a dual H-Bridge motor driver which allows speed and direction
control of two DC motors at the same time. The module can drive DC motors that
have voltages between 5 and 35V, with a peak current up to 2A.
19.SPDT Relay Module

Single Pole Double Throw (SPDT) relays have been described in the previous
section. They can control one circuit because of a single pole but the relay can
have two positions – Normally Open (NO) or Normally Closed (NC).
20.Wooden Body
SPECIFICATION
Left Hard Board Center Hard Board Right Hard Board
Page 34
3.1.3 System constraints
Project constraint
A project constraint is a factor that limits the execution of the project. For
example, cost constraints limit the budget on a project. Traditionally project
managers were primarily looking at only three constraints. They are Scope, time
& cost constraints. When changes occur in the project, project manager assess the
changes for the impacts in the project from these triple constraint’s perspective.
Triple constraints also referred as project management triangle.
Triple Constraints
When there is a change in one of these triple constraints, it impacts the other two
constraints. This fact is referred as triple constraints in the project management.
Figure 3.1.3: 3 Constraints of Project

For instance;
1. If the scope of a project changes, then time & cost of the project also changes.
2. If the time of a project changes, then scope & cost of the project also changes.
3. If the cost of a project changes, then scope & time of the project also changes.
Page 35
When one of these triple constraints are changes, if other two constraints are not
taken care, then obviously it impacts the “quality” of the project. As & when the
changes occur in any of the triple constraints of the project management, the
project manager simply should not accept every change. Instead, the project
manager needs to direct all the changes through perform integrated change
control process to assess the impact of the triple constraints of the project
management & accordingly decide whether to accept or reject the change.
6 Constraints Project
Any time there is a change in your project, you need to manage all six project
management constraints. Otherwise, the project is going to be risky.
Figure 3.1.3: 6 Constraints Project
Here are the 6 constraints of project management.

1. Scope Constraints:
Need to manage the scope of work you do for the project.
2. Time Constraints:
Project will have to be with in the specified time duration.
3. Cost Constraints:
Project will always have to be within the project budget.
Page 36
4. Resource Constraints:
Human resources & other materials required to complete the work.
5. Risk Constraints:
If you don’t deal with the risks, any unexpected things may impact the project
negatively.
6. Quality Constraints:
Project needs to fulfill all the requirements, expected from the project.
3.1.4 External Interface Requirements

External interface requirements are types of functional requirements. They are
important for embedded systems. And they outline how your product will
interface with other components. These requirements include user interfaces,
screen layouts, buttons, functions on every screen, hardware interfaces, & other
relevant particularities. Also, software interfaces like frontend & backend stack,
database management system, etc. must be included.
There are several types of interfaces you may have requirements for, including:
• User
• Hardware
• Software
• Communications
3.2 Functional Requirements

These are the statements describing what the system does; they capture the
functionality of the system. Functional requirements are the statements of
services the system should provide. These statements will represent the reaction
to particular inputs, behaviour in particular situations, abnormal behaviour etc.
sequencing & parallelism are also captured by functional requirements. Usually,
the customers & developers have their focus on functional requirements.
Page 37
3.2.1 Use Cases
Figure 3.2.1: Use Cases Diagram

3.2.2 Activity/Flow Chart Diagram
Figure 3.2.2: Activity/Flow Chart Diagram
Page 38
3.2.3 Sequence Diagram
Figure 3.2.3: Sequence Diagram
3.2.4 ER-Diagram
Figure 3.2.4: ER Diagram
Page 39
3.3 Non-Functional Requirements
Requirements documents not only describe the services system performs but they
must also describe the constraints under which it will operate. These constraints
are restrictions for software developers about the design & construction of
software. These kinds of requirements are called non-functional requirements.
The attributes of functional requirements may be timing, performance, reliability,

accuracy, security, ease of use, regulations, standards, contracts etc. Non-
functional requirements arise through user needs, external factors, safety
regulations, privacy legislation, budget, constraints etc. Sometimes failure to
meet non-functional requirements may make the whole system unusable e.g.,
failure of performance requirements in real time control system will make the
control function to not operate correctly thus making the system unreliable.
3.3.1 Performance Requirements

There are two types of requirements in software requirements specifications:
functional & nonfunctional. Consider performance requirements as a type of
quality attribute, a type of nonfunctional requirements. Performance requirements
define how well the software system accomplishes certain functions under
specific conditions. Examples include the software's speed of response,
throughput, execution time & storage capacity. The service levels comprising
performance requirements are often based on supporting end-user tasks. Like
most quality attributes, performance requirements are key elements in the design
& testing of a software product.
A development team should consider performance requirements along with other

types of quality attributes: reliability, robustness, security & usability as well as
availability, interoperability, safety, efficiency & flexibility. Although gathering
requirements is an essential part of the software development process, it can be a
daunting challenge. The three principal problems in gathering performance
requirements are scope, skill & stability.
Page 40
3.3.2 Security Requirements
Implementation guidance for this control specifies that an organization should
integrate information security into their project management method. As a part of
this integration, it should identify various risks & take the necessary steps to
address those risks. To clarify, this must apply to all types of projects, including
those focusing on core business processes, IT, development, facility management,
etc. An ideal project management method should include:
• Consideration of information security objectives while undertaking

discussions on overall project objectives;
• Conducting information security risk assessment at an early stage of the
project for identifying necessary controls.
• Including information security in all the phases of the project methodology.
In addition, organizations should conduct regular reviews & address information

security implications for their projects. They should define relevant roles for
designating individuals with information security responsibilities in their project
management method. Like this, the privacy by design principle requires
organizations to incorporate privacy considerations throughout the engineering
project. It is an example of a value sensitive design where organizations consider
human values throughout the process. Under Article 25, GDPR incorporates
privacy by design & default principles.
Another parallel can be drawn from the DevSecOps methodology. It stands for
development, security, & operations. While DevOps is a well-known software
development approach, DevSecOps is a relatively new concept. This approach
seeks to implement security practices at the same scale & speed as development
& operations. As a result, organizations pay attention to security considerations
throughout the development process.
Page 41
CHAPTER 4
SYSTEM IMPLEMENTATION
4.1 System Development Process
It is also known as the system development life cycle SDLC, is a term used in the
development of software where a set of methodical processes, activities, are used
to develop & implement a system. With the rapid development & constant
evolution of systems technologies to date, different development processes have
been established & tried. Though each of these processes has been developed with
a specific design in mind, we will find that many of them share common tasks &
are geared towards the same goal.
Systems Development Life Cycle
Figure 4.1: Systems Development Life Cycle Diagram

1. Planning: Put a project manager in place to make a project plan. What system
is going to be built? Answer A registration system. How long will it take?
How much will it cost? Who will build it?
2. Analysis: Done by a systems analyst and a business analyst. Identify the

problem with the old system. In the case of Kean, the old registration system
required students to stand in line to register.
Page 42
3. Design: Also done by a systems analyst. Design a solution to the problem. In
the case of registration, Kean designed a web-based system called Kean Wise
where students could register anytime and from anywhere.
4. Development: Also called construction. This where the hardware, software,

networks & DB are purchased. Done by programmers, network
administrators, DB administrators, & other technicians.
5. Testing: Verify that the system works & meets the needs of the users. Often
uses Quality Assurance personnel.
6. Implementation: Write manuals, train users, switch from old to new system.
7. Maintenance: Help Desk, service management.
4.2 Simulation Model

It is the process of creating & analyzing a digital prototype of a physical model
to predict its performance in a real world. It is used to help designers understand
whether, under what conditions, & in which ways a part could fail & what loads
it can withstand. It can also help to predict fluid flow & heat transfer patterns. It
analyzes the precisely working conditions by applying the simulation software.
Uses of Simulation Modeling:

It allows designers to avoid the repeated building of multiple physical prototypes
to analyze designs for new parts. Before creating the physical prototype, users
can investigate many digital prototypes. Using the technique, they can:
• Optimize geometry for weight and strength.
• Select materials that meet weight, strength, and budget requirements.
• Simulate part failure and identify the loading conditions that cause them.
• Assess extreme environmental loads not easily tested on physical prototypes,
such as earthquake shock load.
• Verify hand calculations.
• Validate the likely safety & survival of a physical prototype before.
Page 43
4.3 System Frame Work/System Architecture
System Architecture:
It is a conceptual model that describes the structure & behavior of multiple
components & subsystems like multiple software applications, network devices,
hardware, & even other machinery of a system. It is ADL which is helps to
describe the entire system architecture. So, it is a much broader topic. It can be
broadly categorized into centralized & decentralized architectural organizations.
Figure 4.3: System Architecture Diagram

4.4 Mathematical Model
In a LGD factory, one technician needs to run multiple reactors, using the sample
route sheet to find out 1) how many reactors you suggest the technician to run,
assume: the distance b/w reactors are 2 minutes away. 2) if operation # D2025
takes 20days (24hr/day), how many reactors you suggest the technician to run?
Page 44
Table 4.3: Table For Route Sheet (Sample)
Goal:
To determine the optimum number of machines to assign an individual operator.
Define:
a = activity time (e.g., loading and unloading a machine)
b = independent operator activity time (e.g., walking, inspecting, packing)
t = independent machine activity time (e.g., automatic machine time)
n' = ideal number of identical machines to assign an operator
Tc = repeating cycle time
I0 = idle operator time during a repeating cycle
Im = idle time for each machine during a repeating cycle
Excluding idle time, each machine cycle requires a + t minutes to complete a

cycle. Likewise, the operator devotes a + b minutes to each machine during a
cycle. Hence, an ideal assignment is,
n' = (a + t) / (a + b) ......................... (2)
In the above example, a = 2 min, b = 1 min, & t = 6 min. Therefore, n' = 2.67
machines.
4.5 Algorithms/API/Packages Used

Algorithms
The process algorithm explains the working of the system in detail. The material
is initially fed in the hopper. The flap is opened by the pneumatic cylinder
Page 45
arrangement, the material falls in the rotating bowl which is measured by the load
cell. The load cell sends a signal to the microcontroller after a fixed amount of
material falls in to the bowl. The microcontroller immediately closes the flap. The
signal to heat sealer piston is sent, the piston actuates & the heat sealer makes the
vertical edge seal & the horizontal seal of the pouch, after a time delay the piston
moves back to its original position which discontinues the contact of the heat
sealer & the plastic pouch. After the seal the bowl rotates & the weighed material
falls in the pouch which is open from top but sealed from bottom. The bowl
returns back to its original position after a suitable time delay. When the bowl
returns to its original position the flap of the hopper is opened & the cycle starts
again. Meanwhile the draw rollers pull the formed plastic downwards by the
length of one bag. The top seal of the pouch is done when the bottom seal of the
next bag is made. Thus, a filled pouch separates from the next pouch when the
top seal is made with the help of a horizontal sealers.
Figure 4.5: Algorithms Diagram
Page 46
4.6 Database Design & Development
DB Design is a collection of processes that facilitate the designing, development,
implementation & maintenance of enterprise data management systems. Properly
designed database is easy to maintain, improves data consistency & are cost
effective in terms of disk storage space. The database designer decides how the
data elements correlate & what data must be stored.
The main objectives of DB design in DBMS are to produce logical & physical
designs models of the proposed database system.
The logical model concentrates on the data requirements & the data to be stored
independent of physical considerations. It does not concern itself with how the
data will be stored physically.
The physical data design model involves translating the logical DB design of the
database onto physical media using hardware resources and software systems
such as database management systems (DBMS).
DB Design & Development Life Cycle
Figure 4.6: DB Design & Development Life Cycle Diagram
The DB design & development life cycle has a number of stages that are followed
when developing DB systems. The steps in the development life cycle do not
necessarily have to be followed religiously in a sequential manner. On small DB
systems, the process of DB design is usually very simple & doesn’t involve a lot
of steps. In order to fully appreciate the above diagram, let’s look at the individual
components listed in each step for overview of design process in DBMS.
Page 47
1. Requirements Analysis
• Planning: These stages of DB design concepts are concerned with planning
of entire DB Development Life Cycle. It takes into consideration the
Information Systems strategy of the organization.
• System Definition: This stage defines the scope & boundaries of the proposed
DB system.
2. Database Designing
• Logical Model: This stage is concerned with developing a DB model based
on requirements. The entire design is on a paper without any physical
implementations.
• Physical Model: This stage implements the logical model of the DB taking
into account the DBMS & physical implementation factors.
3. Implementation
• Data Conversion & Loading: This stage of relational DB design is concerned
with importing & converting data from the old system into the new DB.
• Testing: This stage is concerned with the identification of errors in the newly
implemented system. It checks the DB against requirement specifications.
4.7 GUI DESIGN

Creating a GUI, which allows users to directly interact with their devices &
complete certain tasks by manipulating elements like icons & scroll bars, is one-
way designers make their digital devices more efficient & usable.
Simply put, GUIs help your users do things within your device, platform,
program, without needing to type the coding behind the action.
Some specific examples are:
• Moving a document into the “Trash” folder on your desktop
• Clicking on an icon to launch an application
• Moving files from one folder to another
Page 48
GUI Work
GUIs consist of graphical elements that users interact with. The most common
paradigm of GUIs is the WIMP. The WIMP paradigm refers to virtual input
devices controlled by a physical pointing device; the content containers, &
graphical objects used to initiate some actions. Most GUIs reference the MVC
pattern. This pattern separates internal representations of information from the
manner in which users receive it. The controller acts as a medium b/w 2 parties.
Model View Controller (MVC)
Figure 4.7: MVC Pattern in GUI Design Diagram
Page 49
RESULTS & DISCUSSION
5.1 Result
The modification of the existing VFFS packaging system was carried out giving
importance to the production output on demand. The concept of Mechatronics
systems was implemented to develop this low-cost automated packing system.
The future scope for developing the system includes the addition of machine
vision systems to detect flaws in packing & introducing flexible low-cost
automation systems for complete operation without human intervention.
S.NO. TIME PACKET WEIGHT (gm)

01 1 Minute 11 – 12 Packets 20 gm
Table 5.1: Table of Result
5.2 Discussion
As we see those 20 gm of pouches are packing 11 – 12 packets in a minute. So,
as compared to 30 gm of pouches are packing 09 – 10 packets in a minute. Now
we again testing with 40 gm of pouches now they are packing 07 – 08 packets in
a minute. At the last we finally test the 50 gm of pouches now they are packing
06 – 07 packets in a minute.
Page 50
CHAPTER 6
CONCLUSION & FUTURE DIRECTIONS
6.1 Conclusion
With the proposed of this design, it has been verified that the production rate is
from 6 – 12 pouches per minute. The key parameters under study were production
rate, machine size & hopper capacity. The production rate has been increased
around 50%, the machine size was also reduced about 5%, & also the overall
hopper capacity was increased about 55% as compared to the existing system.
This allows us to achieve the production target with a low operational cost, high
accuracy & less contamination. The comparison chart between the existing &
modified system is shown in the Figure.
Figure 6.1: Chart Figure For System
Page 51
6.2 Future Directions
This machine is used for a wide application in industries. Since the machine is
automating the process of weighing, packing & sealing at a very low cost, further
research will lead to sophistication of the machine. This automatic weighing &
packaging machine can be used in packaging industries, food, pharmaceutical,
dairy products industries. More research will lead to minimization of automation
cost for large scale industries also. Integration of AI is recommended which can
be used for more complex operations. By using FTP, the packaging & material
handling by fully automated process without any human intervention. By use of
ladder program, the processes such as adding input & output devices can also be
automated. This project are useful for related researches in future for conducting
advance researches on Automatic Packaging Machines using Microcontrollers.
This can be helpful in other industries too, resulting in safe operating system,
efficient packaging, fast response time & a small number of workers.
Page 52
REFERENCES
________________________________________________________________________________________
[1] VFFS History & current market, Vertical Form Fill Seal Machine Triple
Expo. Triple Expo. Retrieved, 2019-05-23.
[2] Kittur Ravi Ashok, Design & Force Analysis of Slider Crank Mechanism for
Film Transport Used In VFFS Machine, International Research Journal of
Engineering & Technology (IRJET), Volume 4, Issue 12, Dec. 2017. Pp. 41-47.
[3] Roland Basque, Convertible computer controlled FFS bagging machine,

U.S. Patent US10/794,522, July 18, 2006.
[4] John Schneider, Steven Austin, Gregory Crunkleton, Basil Linton, Eric
Fenzl, Methods of manufacturing slider-operated string-zippered bags on VFFS
machine, U.S. Patent US10/903,453, July 30, 2004.
[5] Roland Basque, Geoff J. Knowers, Vertical form, fill & seal machine for
handling large pouches, U.S. Patent US10/339,826, July 12, 2004.
Page 53

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FINAL YEAR PROJECT REPORT

Automatic Vertical Form Fill Seal (VFFS) Powder

THESIS SUBMITTED TOWARDS THE PARTIAL FULFILMENT OF THE REQUIREMENT OF THE

SYED DAYYAN ASKARI (2102 – 2018)

Department of Electronics Engineering

A project is to be submitted in the partial fulfillment of the

Department of Electronics Engineering

Bachelor of Technology (Electronic) Engineering

Acknowledgement is due to Faculty of Engineering Science & Technology for

We wish to express our appreciation to our Supervisor (Engr. Sheikh Zia Ur

LIST OF TABLES VII

LIST OF FIGURES VIII

CHAPTER 1 INTRODUCTION 1–3

1.1 PROJECT OVERVIEW 1

1.2 PROBLEM STATEMENT 2

1.3 AIM & OBJECTIVES 2

1.4 SCOPE OF THE PROJECT 3

CHAPTER 2 BACKGROUND & LITERATURE REVIEW 4–9

2.1.1 MANAGEMENT INFORMATION SYSTEM 4

2.2.1 NETSUITE RESOURCE MANAGEMENT SYSTEM 4

2.3.1 CLARIZEN RESOURCE MANAGEMENT SYSTEM 5

2.2 LITERATURE REVIEW 5

2.3 COMPARATIVE STUDY 8

CHAPTER 3 RESEARCH/SYSTEM DESIGN 10 – 41

3.1 SYSTEM METHODOLOGY 10

3.1.1 SOFTWARE REQUIREMENTS 10

3.1.2 HARDWARE REQUIREMENTS 26

3.1.4 EXTERNAL INTERFACE REQUIREMENTS 37

3.2 FUNCTIONAL REQUIREMENTS 37

3.2.1 USE CASES 38

3.2.2 ACTIVITY/FLOW CHART DIAGRAM 38

3.2.3 SEQUENCE DIAGRAM 39

3.3 NON-FUNCTIONAL REQUIREMENTS 40

3.3.1 PERFORMANCE REQUIREMENTS 40

3.3.2 SECURITY REQUIREMENTS 41

CHAPTER 4 SYSTEM IMPLEMENTATION 42 – 49

4.1 SYSTEM DEVELOPMENT PROCESS 42

4.2 SIMULATION MODEL 43

4.3 SYSTEM FRAME WORK/SYSTEM ARCHITECTURE 44

4.4 MATHEMATICAL MODEL 44

4.5 ALGORITHMS/API/PACKAGES USED 45

4.6 DATABASE DESIGN & DEVELOPMENT 47

4.7 GUI DESIGN 48

CHAPTER 5 RESULTS & DISSCUSSION 50

CHAPTER 6 CONCLUSION & FUTURE DIRECTIONS 51 – 52

6.2 FUTURE DIRECTIONS 52

TABLE 1 TABLE OF CONTENTS

TABLE 2 LIST OF TABLES

TABLE 3 LIST OF FIGURES

TABLE 2.3 TABLE OF COMPARATIVE STUDY

TABLE 3.1.2 TABLE OF COMPONENTS

TABLE 4.4 TABLE FOR ROUTE SHEET (SAMPLE)

TABLE 5.1 TABLE OF RESULT

FIGURE 3.1.3 3 CONSTRAINTS PROJECT

FIGURE 3.1.3 6 CONSTRAINTS PROJECT

FIGURE 3.2.1 USE CASES

FIGURE 3.2.2 ACTIVITY DIAGRAM

FIGURE 3.2.3 SEQUENCE DIAGRAM