THE MISSION
The goal of the project was to build a nearly fully automatic and extremely space-saving bottling plant for jars. The idea was born out of the need for an alternative to often environmentally harmful portion packaging in the gourmet sauce sector: gourmet sauces should be filled into eco-friendly jars in portion sizes of 30 ml.
Existing industrial systems are often not profitable for small quantities because setup and cleaning times are out of proportion to production volumes. As a result, small quantities are often filled and sealed manually with high personnel costs, significantly increasing production expenses.
The FILL-O-MATIC 9001 combines various functions more compactly than standard market modules. It is designed for ergonomic operation by a single person and aims for a production capacity of up to 1200 jars per hour. The concept relies on low-maintenance technology and a space-saving solution for small production volumes.
THE REQUIREMENTS
To build a practical machine, clear technical specifications were defined:
- Footprint: Minimal area for single-person operation.
- Buffering: Sufficient accumulation and buffer sections for short-term secondary tasks (QA, logging).
- Electronics: Reduced design, 24V operation.
- Capacity: Cycle rate of 20 jars per minute.
- Materials: Food-grade, product-contact parts heat-resistant up to 90°C.
- Costs: Focus on an economical, affordable solution.
THE FUNCTIONS
The machine handles the entire process from empty jar to sealed container:
- Storage for empty containers and lids.
- Lid provisioning in the correct orientation.
- Automatic feeding into the filling process.
- Jar Turner: Flipping jars before filling to remove foreign objects.
- Gravimetric Filling: 100% control through direct weighing during filling via a peristaltic pump.
- Automatic lid placement and screwing.
- Buffer area for finished full containers.
PROTOTYPES & DEVELOPMENT
The path to the finished machine was an evolutionary process:
- Phase 1: Concept verification using a wooden variant and 3D-printed components.
- Evolution: Expansion from a single-head to a double-head filler (16-station transport star).
- Jar Turner Optimization: From a simple tilting device to a gravity-driven spiral and finally to a space-saving, driven disk.
- Lid Sorting: Perfecting the hopper system for 100% correct orientation.
TECHNICAL DETAILS & COMPONENTS
The FILL-O-MATIC 9001 is powered by a Raspberry Pi acting as a central controller, interfaced with a wide array of Tinkerforge modules for precise hardware control.
Hardware Mapping
The machine uses a modular approach with industrial-grade feeds. Numbering follows the working direction of the jars.
| Feed | Hardware | Module |
|---|---|---|
| 1 | Bunker stepper | Silent Stepper Brick |
| 2 | Bunker light barrier | GPIO16V2 Bricklet |
| 3 | Turntable stepper | Stepper Brick |
| 4 | Turntable light barrier | GPIO16V2 Bricklet |
| 5-6 | Closer motors (Drills) | Performance DC Bricklet 1 |
| 7-8 | Closer clamps & head | Relais Bricklet |
| 9-10 | Scales 1 & 2 | Load Cell Bricklet 2.0 |
| 11-13 | Filler & Refeed | Relais Bricklets |
| 14 | Glass turner motor | Performance DC Bricklet 2 |
For the closer motors, we used modified Einhell drills that are driven up and down by pneumatic actuators to handle the lid screwing process with consistent torque.
Control System & UI
The machine creates its own localized WiFi network for management and monitoring.
- Controller: Fire HD 8 Tablet (configured in restricted mode).
- Networking: Raspberry Pi in Access Point mode (
FillOMatic9001AP). - Protocol: Communication via MQTT.
TECHNICAL DATA
| Component | Details |
|---|---|
| Jar | 50 ml / 51 mm Height / 47 g / GL 43 Thread |
| Lid | Twist-Off / 43 mm Ø / Black |
| Electronics | 24V Control System |
IN RETROSPECT
The FILL-O-MATIC 9001 was a passionate COVID hobby project. It served as a digital and mechanical playground to explore the limits of home automation and compact engineering.
While the machine fulfilled all requirements as a fully functional prototype and successfully demonstrated the entire bottling process, it was never intended for or used in real-world production. With the end of pandemic restrictions, this chapter of the “Workbench” was also successfully closed. It remains a testament to what can be created in a garage with curiosity, 3D printing, and a lot of free time.