International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 06 | Jun 2025
p-ISSN: 2395-0072
www.irjet.net
Development and Performance Evaluation of Automatic Viscous Fluid Filling System Prof. Sumit Vitthal Patil, Suraj Balaso Patil, Akshay Arun Vibhute, Yash Bajirao Surve ADCET College of Engineering & Technology, Ashta, Sangli ---------------------------------------------------------------------***--------------------------------------------------------------------been upgraded with pneumatic drives and automated valves Abstract
to handle a wide variety of semi-liquid and viscous substances. These systems often include level sensors for improved control. Duncan and Redan (2018) highlighted contamination risks associated with food-grade lubricants in piston filling machines, emphasizing the importance of hygiene and precision in filling equipment, especially for food and pharmaceutical applications. Meah (2010) proposed an Arduino-based low-cost liquid filling machine aimed at smallscale industries that cannot afford high-end PLCs. This system offered adequate precision while maintaining a simple design, making it accessible for educational and industrial use. Lad and Lodewijks (2002) discussed the costbenefit advantages of semi-automatic filling machines that integrate stepper motors and non-return valves to ensure flow control and accuracy in viscous fluid dispensing. Guha and Ganzeer (2000) explored ways to reduce labour involvement in repetitive manufacturing operations through automation, identifying filling as one of the processes most in need of technological intervention. These studies collectively support the need for affordable, flexible, and efficient fluid filling systems in diverse industrial settings.
This paper presents the design and performance evaluation of an automated viscous fluid filling system using Arduinobased control and proximity sensors. The system aims to address challenges in manually filling high-viscosity fluids such as oils and gels, which typically result in inconsistent output and increased operator fatigue. The proposed setup integrates sensor-actuated pneumatic systems controlled by Arduino, ensuring precise fluid dispensing and improved ergonomics. Performance analysis was conducted using time and method study techniques. The system exhibited enhanced efficiency, consistency, and reduced cycle time, making it viable for smallscale industrial applications.
Keywords: Arduino, Proximity Sensor, Pneumatics, Viscous Fluids, Time Study, Automation, Ergonomics Introduction Introduction Viscous fluids such as oils, gels, and syrups are used extensively in food, cosmetics, pharmaceuticals, and lubrication industries. These fluids possess high internal resistance to flow, which makes their handling and dispensing more challenging compared to low-viscosity fluids. Manual filling of such fluids leads to several issues including spillages, inaccurate fill volumes, high rejection rates, and physical strain on operators. With increasing demand for speed and consistency in industrial operations, manual processes are no longer viable for medium- to highvolume production. Automation in the form of microcontroller-based filling systems presents a solution to this problem. Arduino-based platforms offer flexibility, affordability, and ease of integration with sensors and actuators. This research focuses on the development of a semi-automated viscous fluid filling system controlled via Arduino, utilizing proximity sensors to detect containers and pneumatic cylinders for fluid actuation. The primary objective is to enhance the accuracy, consistency, and ergonomic aspects of the filling process, ultimately improving operational efficiency for small to medium enterprises.
Problem Statement and Objectives Manual filling of high-viscosity fluids is labor-intensive and leads to inconsistent volumes, ergonomic strain, and reduced productivity. Conventional systems lack automation, are inefficient for continuous operations, and pose challenges in handling varying container sizes and fluid types. To address these gaps, this project develops a semi-automated fluid filling system using Arduino and pneumatic technology.
Objectives •
Redesign the workstation for ergonomic and continuous production.
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Integrate sensors with Arduino for automated control.
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Employ pneumatic actuation.
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Validate performance with time and method studies.
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Ensure accuracy across different fluid viscosities and container dimensions.
Literature Review Literature Review The evolution of automated fluid dispensing has been extensively documented in both academic and industrial literature. Krainev (2010) discussed how traditional volume-based piston pump systems have
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