International Journal of Current Engineering and Technology E-ISSN 2277 – 4106, P-ISSN 2347 – 5161 ©2016 INPRESSCO ® , All Rights Reserved Available at http://inpressco.com/category/ijcet Research Article 420| MIT College of Engineering, Pune, India, AMET 2016, INPRESSCO IJCET Special Issue-4 (March 2016) Design and Development of Cost Effective Automatic Machine for Powder Packaging M. R. Saraf †* , V. V. Ruiwale † , V. V. Kulkarni † and S. M. Kulkarni † † Mechanical Engineering Department, MITCOE, Sri Savitribai Phule Pune University, Pune, Maharashtra, India Accepted 02 March 2016, Available online 15 March 2016, Special Issue-4 (March 2016) Abstract The packaging industry has advanced leaps and bounds over the few years. The pouch packaging machines also known as Form Fill and Seal Machines (FFS Machines) are available over a wide capacity range. A low cost automated packing machine can be used by small enterprises which would help reduce their cost of plant. This low cost automated machine uses simple pneumatic, mechanical and electric systems. In this paper we have presented one such low cost pouch filling machine. An additional weighing and pouring mechanism has been added to increase the accuracy of the system. The process flow has been described in detail. Various processes involved in the pouch packaging are neatly aligned and properly timed to get optimum production rate. A mechatronics system, developed for this machine, which takes feedback from sensors and accordingly controls the manipulators has been introduced in this paper. A microcontroller system is used for this particular machine. A detailed cost comparison between a conventional machine and the one developed by us has been presented. Keywords: Low Cost Automation, Microcontroller, PLC 1. Introduction 1 In the current global scenario better quality, low cost with higher productivity are major factors for any enterprise to flourish. To cope up with the ever increasing market competition, low cost automation is the safest strategy. Low Cost Automation comprises the use of standard components to mechanize or automate machines, processes and systems. These low cost automated machines can be operated by semi-skilled or unskilled labors as it requires limited human intervention. In this paper need of automation, types of automation, design, process flow and cost comparison have been described. 2. Literature Review Pouch packing machines are commonly known as Form Fill and Seal Machines. There are classified as two main types– Vertical Form Fill and Seal Machines and Horizontal Form Fill and Seal Machines. Vertical Form Fill and Seal Machines (VFFS Machine) are used to pack regular shaped solid products or liquids while, Horizontal Form Fill and Seal Machines are used to pack irregular shaped products. In this paper we focus on the Vertical Form Fill and Seal Machines. VFFS machines are widely used in most of the industries to pack products of various sizes (depending on their weights). *Corresponding author: M. R. Saraf The VFFS Machines are again classified in two ways- According to their type of motion (Continuous motion and Intermittent motion) and According to their type of automation (Fully automated and Semi automated). In making of the pouch two seals have to be made