This project involved designing and implementing an automated system for filling and packaging volatile liquids into vials, replacing manual processes with a more reliable and safer alternative. The system integrates an electronic liquid handling device, linear actuator, pneumatic thermal press, reed switches, and a PLC to streamline the entire operation. The operator places an empty vial into the nest and the process is triggered by a simple touch button to initiate the vial filling and heat-sealing by aluminum disc.

Key contributions included wiring and assembling all mechanical, electronic, and sensor components, verifying electrical connections via schematics and multimeter testing, and interfacing the PLC, liquid handling device, and linear actuator using RS-232 protocols, Ladder Logic, and OEM software. A Design of Experiment (DOE) was conducted to optimize fill accuracy, repeatability, and speed, and a formal operation and maintenance manual was authored and released.

The effort delivered measurable results: cycle time was reduced by 30%, and volume dispensing precision was brought to within ±1% of requirements.