DESIGN AND DEVELOPMENT OF AN INDUSTRIAL FORM-FILL-SEAL (FFS) PACKAGING MACHINE
AUTHORS:
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Prof. V. B. Baru
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Dept. of Electronics and Telecommunication Sinhgad College of Engineering Pune, India
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Abstract
Form-Fill-Seal (FFS) machines are widely used in packaging industries to automate the processes of forming, filling, sealing, and cutting packages. However, industrial FFS machines are costly, mechanically complex, and not suitable for classroom demonstrations or introductory training in automation systems. To address this limitation, a compact PLC-HMI based FFS demonstration platform was developed to represent the operating sequence of an industrial packaging machine in a safe and simplified manner.
The developed system uses a B&R Power Panel C50 integrated controller and Human-Machine Interface (HMI) operating on a 24 V DC supply. Sixteen toggle switches are used to simulate machine inputs, while sixteen LED indicators represent machine outputs such as film feeding, filling, sealing, cutting, and alarm conditions. The control sequence was implemented using PLC logic and tested under different operating conditions to verify correct system behaviour.
Experimental testing confirmed reliable execution of the programmed sequence and proper response to start, stop, and emergency commands. The developed platform provides a practical way to demonstrate industrial automation concepts, PLC programming, HMI operation, and machine-sequence control without the safety risks and cost associated with a full-scale packaging machine
The developed system uses a B&R Power Panel C50 integrated controller and Human-Machine Interface (HMI) operating on a 24 V DC supply. Sixteen toggle switches are used to simulate machine inputs, while sixteen LED indicators represent machine outputs such as film feeding, filling, sealing, cutting, and alarm conditions. The control sequence was implemented using PLC logic and tested under different operating conditions to verify correct system behaviour.
Experimental testing confirmed reliable execution of the programmed sequence and proper response to start, stop, and emergency commands. The developed platform provides a practical way to demonstrate industrial automation concepts, PLC programming, HMI operation, and machine-sequence control without the safety risks and cost associated with a full-scale packaging machine
Keywords
Form-Fill-Seal PLC HMI packaging automation industrial control ladder logic.
Article Information
PUBLICATION DETAILS
Review Type:
Double-Blind Peer Review
License:
CC BY-NC 4.0
Volume/Issue:
Volume 02, Issue 6
Review Rounds:
2
Article Type:
Research Article
Publication Date:
Jun 20 2026
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Pachpol, K. Y., Kadam, S. V. & Girme, P. N. (2026). Design and Development of an Industrial Form-Fill-Seal (FFS) Packaging Machine. International Journal of Science, Strategic Management and Technology, 02(6). https://doi.org/10.55041/ijsmt.v2i6.162
Pachpol, Kartik, et al.. "Design and Development of an Industrial Form-Fill-Seal (FFS) Packaging Machine." International Journal of Science, Strategic Management and Technology, vol. 02, no. 6, 2026, pp. . doi:https://doi.org/10.55041/ijsmt.v2i6.162.
Pachpol, Kartik,Shruti Kadam, and Pratiksha Girme. "Design and Development of an Industrial Form-Fill-Seal (FFS) Packaging Machine." International Journal of Science, Strategic Management and Technology 02, no. 6 (2026). https://doi.org/https://doi.org/10.55041/ijsmt.v2i6.162.
References
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