Design of the Prototype

Top View
Front View
Left View
Isometric View
Objectives of the Study

The main objective of this study is to design and develop a small scale bottle

filling and capping machine for dishwashing liquid. Specifically, this project aims to:

1. Design a bottle filling and capping machine taking into consideration the

following:

1.1. Material Specification

1.2. System Components

2. Fabricate a bottle filling and capping machine taking the design specifications

into account.

3. Conduct preliminary testing of the fabricated bottle filling and capping machine to

determine the following:

3.1. Filling Time

3.2. Capping Time

3.3. Operating Time

4. Evaluate the performance of the bottle filling and capping machine in terms of:

4.1. Filling Rate

4.2. Filling Efficiency

4.3. Capping Rate

4.4. Capping Efficiency

4.5. Overall Production Rate

5. Provide cost-benefit analysis to establish the economic viability of the machine.

6. Provide an operation and maintenance manual for the bottle filling and capping

machine.
 CHAPTER III
RESEARCH METHODS AND PROCEDURES

This chapter covers the fundamental principles of the study's concepts, as well as

the research development techniques and methodologies that will be applied to the

bottle filling and capping machine for dishwashing liquid. This will also give a general

summary of the actions that must be taken to accomplish the objectives of the study.

Conceptual Framework

The study will focus on the design and development of bottle filling and capping

machine for dishwashing liquid, specifically for the Brgy. Libjo Livelihood Training

Center. In presenting the concepts, the Conceive-Design-Implement-Operate (CDIO)

Model will serve as the foundation for the conceptual framework of this study.

The first stage of the CDIO Model is the conceive stage which will consider the

knowledge requirements necessary for the design and development of the machine.

These are the knowledge regarding the dishwashing liquid to be filled and capped,

dishwashing liquid production process, existing method of filling and capping, and

efficiency of existing method of filling and capping.

The second stage is all about the design of the prototype wherein it includes

various design requirements such as layout of the design, the construction of the

machine, material specifications, system components and parts of the machine, the

dimension of the machine component, the availability of materials, and as well as the

software will be used in executing the desired plan for the design of the system,

specifically the CAD software (SolidWorks).

 Then in the third stage, the implementation stage, the fabrication of the bottle

filling and capping machine was taken into account using the locally available materials.

It also included the gathering of the materials and equipment that were used for the

fabrication. Furthermore, preliminary testing of the bottle filling and capping machine will

be accomplished in order to test the various parameters such as filling time, capping

time, and operating time. Through this testing, the researchers will be aware if there will

be some modifications that must be dealt with. Moreover, performance testing will be

conducted to know the filling rate, capping rate, filling efficiency, capping efficiency, and

overall production rate.

A complete and operational bottle filling and capping machine for dishwashing

liquid, as well as its corresponding operating and maintenance manual, will be

developed throughout the operation stage. The project's concept is further clarified by

the visual representation of the intellectual framework presented in the figure, making it

more comprehensible.
CONCEIVE DESIGN IMPLEMENT OPERATE

Figure No. _ Research Paradigm of the Study

Research Design

This study will blend developmental research with engineering design, planning,

and analysis to meet its goals. To create the design, we'll gather relevant facts and

ideas from different sources to give credibility to our research topic. We'll carefully plan

and collect data, like figuring out if the materials and components we want to use for the

prototype are suitable. We'll examine material specifications based on how well the

components can produce the desired results. We'll also follow the

Conceive-Design-Implement-Operate (CDIO) method to set clear objectives and actions

that match our research framework. Providing a detailed overview of our research

approach is crucial for the study's success, outlining precisely how we'll carry out the

project and reach a successful conclusion.

Development Stages

Important elements were taken into consideration in addition to the technical

features, the study's applicability and significance, the available materials, the

requirements, and the demands made by the final product's intended users. This

research took into account several stages of development, including:

1. Design Stage

This stage will address the creation of the bottle filling and capping

machine for dishwashing liquid schematic diagram. This will involve specifying

the system's components, dimensions, and other appropriate fabrication

materials. The different parameters present during the entire process were used

to design each component of the proposed machine.

Design of the Prototype

This section presents the design of the prototype. It includes the main

components and parts of the fabricated tool and its material specifications.

Schematic Diagram of the Bottle Filling and Capping Machine for

Dishwashing Liquid

After considering the related literature discussed in Chapter II, the

schematic diagram of the proposed machine was generated.

Figure No. _ Schematic Diagram of the Machine

 The selection of suitable materials for each component and part will be

taken into account in order to ensure precise and effective operation of the Bottle

Filling and Capping Machine for Dishwashing Liquid. In addition, the sizes and

dimensions of different components will be thoroughly selected to ensure the

connections between them and the effective operation of the machine.

Discussion of Machine Components

A. Cap Slider

The cap slider will typically be constructed from durable materials

such as stainless steel or high-quality plastic. The design incorporates a

path or tunnel system to direct caps towards the bottles, ensuring

continuous controlled movement to avoid any jams or misalignments.

Figure No. _ Cap Slider

B. Capping Mechanism

The capping mechanism is designed to securely seal caps onto

bottles with precision. When utilized with the cap slider, it will ensure

automated accurate alignment and application of caps to bottle openings .

Figure No. _ Capping Mechanism

C. Control Device System

The control device system functions as the central processing unit

of the machine, coordinating the functioning of different components and

guaranteeing a seamless workflow. It controls the procedures of filling,

capping, and other associated operations.

Figure No. _ Control Device System

D. Dishwashing Liquid Reservoir

This is a stainless steel container with a maximum capacity of 119

liters. The reservoir will serve as a storage for the dishwashing liquid raw

material, in preparation of the later filling procedure.

Figure No. _ Dishwashing Liquid Reservoir

E. Filling Mechanism

The filling mechanism will be powered by a magnetic pump,

accurately dispensing volumes of dishwashing liquid into bottles. This

mechanism will guarantee uniformity by accurately regulating the liquid

flow from the dishwashing liquid reservoir to the bottles.

Figure No. _ Filling Mechanism

F. Industrial Turntable

This study will utilize an industrial turntable to improve the transfer

of bottles from the bottle feeder to the final stage. In addition, the turntable

will be used to securely hold the bottles in place during the filling and

capping stages of the process and to assist the movement of bottles.

Figure No. _ Industrial Turntable

G. Magnetic Pump

This will be integrated with the filling mechanism to ensure the

efficient transfer of liquid from the reservoir to the bottles. The pump uses

magnetic force to accurately dispense volumes into each bottle.

Figure No. _ Magnetic Pump

H. Motor

The motor will function as the main source of power for the

dishwashing liquid bottle filling and capping machine, supplying the

required mechanical force to operate both the turntable and the pusher

blade.

Figure No. _ Motor

I. Pusher Blade

The pusher blade will be essential in assisting the movement of

bottles along the production line. It will facilitate the transfer of bottles

from the turntable to the final stage, optimizing the production flow.

Figure No. _ Pusher Blade

2. Fabrication Stage

This phase involves the process of gathering the components and

constructing the prototype in line with the machine's design and specifications.

The operational principles of the machine parts will take priority while looking at

specific pre-existing designs. The design will be characterized by its simplicity,

functionality, and feasibility, with careful consideration of all relevant factors to

achieve the intended result. Decisions will be made appropriately under the

leadership, supervision, and guidance of carefully selected professionals who

possess the necessary credentials and exceptional qualifications. Testing will

begin immediately upon completion of the machine. To optimize the machine's

performance, adjustments will be implemented to improve and address any

deficiencies.

3. Preliminary Testing Stage

Upon completion of fabrication, it is important to carry out preliminary

testing to determine the mechanical effectiveness and performance of the

prototype. The test will be performed to determine the parameters, including the

filling time, capping time, and operating time. This will be conducted to identify

the optimal operating condition.

4. Final Performance Testing

Following a series of changes and upgrades, the machine will undergo a

final performance test. A performance operation will be conducted to assess

criteria including filling rate, filling efficiency, capping rate, capping efficiency, and

overall production rate.

Experimental Testing

During the experimental testing, it is imperative to assess the development stage

of the dishwashing liquid bottle filling and capping machine. The machine will be

subjected to a range of test trials to assess such preliminary parameters, including the

filling time, capping time, and operating time. Furthermore, this experimental testing will

gather data and identify deficiencies, which will then be utilized to make modifications

for the improvement of the machine.

Preparation of Raw Materials

The performance testing of the study will take place at Brgy. Iba West, Taal,

Batangas, where the dishwashing liquid production is located. The community of

women in Brgy. Iba West, Taal, Batangas is facing challenges in the production of

dishwashing liquid due to the frequent requirement to fulfill large orders, in addition to

producing other cleaning products. This dishwashing liquid will be the subject of testing

for the bottle filling and capping machine.

The bottle filling and capping machine will be positioned securely in a location

that allows the user to move around comfortably and where a suitable power source is

available for the machine. The first step entails placing the dishwashing liquid into the

machine's reservoir. In order to advance with the filling procedure, the bottles will be

arranged consecutively at the bottle input station. The bottle caps will be consistently

inserted into the cap slider. Once the operation is completed, the dishwashing liquid will

be filled, capped, and placed at the end of the line.

Methods of Testing

The following methods will be used to determine the following parameters:

Methods of Determining the Preliminary Testing Parameters

A. Method of determining filling time of each bottle

The filling time will start when the bottle reaches the filling area. The filling

mechanism will fill the bottle until the dishwashing liquid reaches the specified

volume. The time will be measured using a time measuring device and will be

recorded for filling.

B. Method of determining capping time of each bottle

The capping time will be measured from the moment the cap is loaded

into the bottle's mouth until the capping mechanism secures and fastens the cap.

C. Method determining the operating time

The operating time of the machine refers to the length of time from when

the bottle filling process begins until it is capped. The entire batch of bottles will

undergo the process, and the duration from the first bottle to the last bottle will be

recorded.

Methods of Determining the Final Testing Parameters

A. Methods of determining the filling rate

The filling rate of the dishwashing liquid bottle filling and capping machine

will be calculated by dividing the total number of acceptable dishwashing liquid

 filled bottles, which has an acceptable volume, that will be produced by the

machine over the filling time.

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑓𝑖𝑙𝑙𝑒𝑑 𝑏𝑜𝑡𝑡𝑙𝑒𝑠

𝐹𝑖𝑙𝑙𝑖𝑛𝑔 𝑅𝑎𝑡𝑒 = 𝑓𝑖𝑙𝑙𝑖𝑛𝑔 𝑡𝑖𝑚𝑒

Equation No. 1 Filling Rate

B. Methods of determining the filling efficiency

The filling efficiency of the machine will be determined by dividing the total

number of acceptable filled dishwashing liquid bottles over the expected number

of filled dishwashing liquid bottles and then multiplying the result by 100 percent.

𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑓𝑖𝑙𝑙𝑒𝑑 𝑏𝑜𝑡𝑡𝑙𝑒𝑠

𝐹𝑖𝑙𝑙𝑖𝑛𝑔 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑒𝑥𝑝𝑒𝑐𝑡𝑒𝑑 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑓𝑖𝑙𝑙𝑒𝑑 𝑏𝑜𝑡𝑡𝑙𝑒𝑠
𝑥100

Equation No. 2 Filling Efficiency

C. Methods of determining the capping rate

The capping rate of the dishwashing liquid bottle filling and capping

machine will be calculated by dividing the total number of acceptable

dishwashing liquid capped bottles, with enough tightness, that will be produced

by the machine over the total capping time.

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑐𝑎𝑝𝑝𝑒𝑑 𝑏𝑜𝑡𝑡𝑙𝑒𝑠

𝐶𝑎𝑝𝑝𝑖𝑛𝑔 𝑅𝑎𝑡𝑒 = 𝑐𝑎𝑝𝑝𝑖𝑛𝑔 𝑡𝑖𝑚𝑒

Equation No. 3 Capping Rate

D. Methods of determining the capping efficiency

The capping efficiency of the machine will be determined by dividing the

total number of acceptable capped dishwashing liquid bottles over the expected

number of capped dishwashing liquid bottles and then multiplying the result by

100 percent.
 𝑡𝑜𝑡𝑎𝑙 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑐𝑎𝑝𝑝𝑒𝑑 𝑏𝑜𝑡𝑡𝑙𝑒𝑠
𝐶𝑎𝑝𝑝𝑖𝑛𝑔 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝑒𝑥𝑝𝑒𝑐𝑡𝑒𝑑 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑐𝑎𝑝𝑝𝑒𝑑 𝑏𝑜𝑡𝑡𝑙𝑒𝑠
𝑥100

Equation No. 4 Capping Efficiency

E. Methods of determining the overall production rate

The overall production rate of dishwashing liquid bottle filling and capping

machine will be calculated by dividing the total number of acceptable bottled

dishwashing liquid that will be produced by the machine over the total operating

time.

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑐𝑒𝑝𝑡𝑎𝑏𝑙𝑒 𝑏𝑜𝑡𝑡𝑙𝑒𝑑 𝑑𝑖𝑠ℎ𝑤𝑎𝑠ℎ𝑖𝑛𝑔 𝑙𝑖𝑞𝑢𝑖𝑑

𝑂𝑣𝑒𝑟𝑎𝑙𝑙 𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑒 = 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒

Equation No. 5 Overall Production Rate

Economic Analysis

The economic analysis involves investigating the allocation of resources by

individuals and organizations for the production of commodities and services, as well as

the distribution and consumption of these goods and services. This study will employ

economic analysis to evaluate the expenses and advantages of utilizing the bottle filling

and capping machine in the production of dishwashing liquid. The utilization of bottle

filling and capping machines will enhance the production process for dishwashing liquid

manufacturers, resulting in benefits for them. The enhancement of productivity and

efficiency in dishwashing liquid production will benefit small business owners and the

members of the community of women at Brgy. Iba West, Taal, Batangas who are

involved in the production of dishwashing liquid.

 However, owning a machine also entails additional costs such as equipment

maintenance, electricity, and other operational charges. In overall, a comprehensive

economic analysis of a bottle filling and capping machine for dishwashing liquid would

entail a thorough evaluation of the expenses and benefits associated with utilizing the

equipment, along with an examination of its profitability and potential impact on the

environment and society.

The following formulas will be used to determine the economic viability of the

bottle filling and capping machine:

Payback Period

𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐸𝑥𝑝𝑒𝑛𝑑𝑖𝑡𝑢𝑟𝑒𝑠 − 𝑆𝑎𝑙𝑣𝑎𝑔𝑒 𝑉𝑎𝑙𝑢𝑒

𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑃𝑒𝑟𝑖𝑜𝑑 = 𝑁𝑒𝑡 𝐴𝑛𝑛𝑢𝑎𝑙 𝐶𝑎𝑠ℎ 𝐹𝑙𝑜𝑤

Equation No. 6 Payback Period

Return of Investment

𝑁𝑒𝑡 𝐴𝑛𝑛𝑢𝑎𝑙 𝑃𝑟𝑜𝑓𝑖𝑡

𝑅𝑂𝐼 = 𝐶𝑎𝑝𝑖𝑡𝑎𝑙 𝐸𝑥𝑝𝑒𝑛𝑑𝑖𝑡𝑢𝑟𝑒𝑠
𝑥100%

Equation No. 7 Return of Investment

Data Collection And Treatment

The researchers will collect data for this project through site visits and interviews

with members of the Brgy. Libjo Livelihood Training Center. Their attention will be on

understanding the difficulties arising from the slow pace production of dishwashing

liquid and the techniques being employed to tackle these problems. The preliminary

testing of the bottle filling and capping machine will involve conducting experimental

tests to evaluate its functionality based on filling time, capping time, and operating time.
The total effectiveness of the product will be determined by the final testing parameters,

which include the filling rate, filling efficiency, capping rate, capping efficiency, and

overall production rate. During the design and building stages, the researchers will

actively seek expert guidance to guarantee that the machine complies with engineering

requirements. The collected data will be systematically arranged and examined.This

data will provide the foundation for the research findings and succeeding sections,

including conclusions and recommendations.

Hardware and Software Requirements

The research focused on SolidWorks, a program recognized for its excellent

representation of solid modeling applications in computer-aided design and engineering.

When designing a suitable bottle filling and capping machine for dishwashing liquid,

SolidWorks takes into account the system's components and specifications as key

design variables. The aforementioned tool will also display the arrangement and

three-dimensional representation of the prototype.

Once the design of the machine has been approved with the necessary

modifications and revisions, the proponents will hand over it to professionals. The

machine shop professionals will supervise the procedure by examining the relevant

materials and performing the necessary trials to achieve the optimal product outcome.
Budget Requirements

The table below displays the projected budgetary needs for the proposed project

referring to the design and development of a bottle filling and capping machine for

dishwashing liquid.

BUDGET REQUIREMENTS

MATERIALS UNIT COST QUANTITY TOTAL COST

Industrial Php 10,000.00 2 Php 20,000.00

Turntable

Filling Mechanism Php 4,000.00 1 Php 3,000.00

Magnetic Pump Php 3,500.00 1 Php 2,500.00

Dishwashing Php 8,000.00 1 Php 8,000.00

Liquid Reservoir

Cap Slider Php 800.00 1 Php 800.00

Capping Php 3,000.00 1 Php 3,000.00

Mechanism

Pusher Blade Php 3,500.00 1 Php 3,500.00

Motor Php 6,500.00 1 Php 6,500.00

Control Box and Php 5,000.00 - Php 5,000.00

Accessories

Structure Php 15,000.00 - Php 15,000.00

Fabrication Php 30,000.00 - Php 30,000.00

TOTAL 97,300

Table No. _ Budget Requirements

Expected Output

Figure No. _ Isometric View of Filling and Capping Machine

Gantt Chart

The progress of study was scheduled based on the anticipated completion date. To ensure timely completion of the

study, the researchers allocated sufficient time for each stage and procedure. The researchers' intended timetable for the

duration of this investigation is displayed in the table below.

Table No. _ Gantt Chart