Mechanical · Machine and manufacturing · Final year project
PLC Operated Color Based Product Sorting Machine
A PLC-controlled sorting line that separates products by colour. Colour sensors identify each item on the conveyor, and two pneumatic cylinders operated by solenoid valves push it into the matching collection bin.
What is the PLC Operated Color Based Product Sorting Machine project?
A PLC-controlled sorting line that separates products by colour. Colour sensors identify each item on the conveyor, and two pneumatic cylinders operated by solenoid valves push it into the matching collection bin.
Key facts
- Branch
- Mechanical & Automobile Engineering; also suits Mechatronics
- Type
- Final year project · Advanced
- Suitable for
- Diploma capstone and B.E / B.Tech final year
- Build time
- 6 to 8 weeks
- Estimated component cost
- ₹17,500 – ₹25,800
- Guidance from
- ₹9,999 (Hardware / IoT Final Year)
How the PLC Operated Color Based Product Sorting Machine works
- The mild steel frame and fabrication forms the base that carries every other part, so it is designed first from the load and size of the machine.
- The DC geared motor provides the driving motion.
- Motion is transmitted through DC geared motor, pulleys and V-belt, shafts and ball bearings with housing, which set the speed, torque and direction at the working end.
- The Valves control the direction and flow of air or fluid.
- The Compact PLC runs the ladder logic that sequences the machine's inputs and outputs, the way industry automates processes.
- The Colour sensor identifies colours for sorting or detection.
- The Push buttons and switches provide manual inputs and the power switch.
Block diagram
Power
Relay moduleDC geared motorTransmission
DC geared motorPulleys and V-beltShafts (machined)Working unit
Valves (solenoid / direction control)Structure
Frame and mountsComponents list and cost
Typical prices from Indian online stores and electronics markets (Lamington Road, Budhwar Peth, SP Road). Buy from one store where you can to save on shipping.
| Component | Qty | What it does | Approx. cost |
|---|---|---|---|
| Compact PLC (e.g. Delta DVP / Siemens LOGO!) | 1 | Runs the ladder logic that sequences the machine's inputs and outputs, the way industry automates processes. | ₹9,500 |
| Colour sensor (TCS3200) | 1 | Identifies colours for sorting or detection. | ₹450 |
| Push buttons and switches | 1 | Provide manual inputs and the power switch. | ₹40 |
| Relay module | 1 | Switches mains or high-current loads such as lamps, pumps and fans from a low-voltage signal. | ₹70 |
| DC geared motor | 1 | Provides the driving motion. | ₹250 |
| LEDs (assorted) | 1 | Indicate status. | ₹20 |
| Pulleys and V-belt | 1 | Transmit rotation between shafts. | ₹350 |
| Valves (solenoid / direction control) | 1 | Control the direction and flow of air or fluid. | ₹900 |
| Shafts (machined) | 1 | Transmit rotation and torque. | ₹400 |
| Ball bearings with housing | 1 | Support rotating shafts with low friction. | ₹250 |
| Mild steel frame and fabrication | 1 | Forms the main structure that holds all parts. | ₹2,500 |
| Welding, cutting and machining labour | 1 | Needed for this type of build. | ₹2,200 |
| Pneumatic Actuator | 1 | Part from the design specification | ₹400* |
| Pneumatic Pipes | 1 | Part from the design specification | ₹400* |
| Proximity Sensor | 1 | Part from the design specification | ₹400* |
| Connecting Rod | 1 | Part from the design specification | ₹400* |
| Roller | 1 | Part from the design specification | ₹400* |
| Joints & Fixtures | 1 | Part from the design specification | ₹400* |
| Mounts, screws, nuts and small hardware | 1 | Enclosure, mounts and fasteners. | ₹300 |
| Paint, finishing and workshop consumables | 1 | Project overhead | ₹600 |
| Transport of material | 1 | Project overhead | ₹400 |
| Estimated total | Varies with brand, quality and city | ₹17,500 – ₹25,800 |
Prices are estimates for budgeting; items marked * depend on the exact size or model chosen. We confirm the bill of materials when your design is frozen, and components are charged at actual cost with bills.
How much does this project cost?
| Option | What you get | Cost |
|---|---|---|
| Components only | You buy the parts and build it yourself | ₹17,500 – ₹25,800 |
| Hardware / IoT Final Year | Working model or guided build, Circuit diagram and bill of materials, Firmware / code with explanation | from ₹9,999 + components |
| Capstone Project (CPE) | Working project or model, Black book in MSBTE format, Step-by-step explanation | ₹9,999 + components |
| Diploma ITR | 100% working source code, Project report PDF, PPT | ₹1,999 + components |
No GST and no hidden charges. Use the cost calculator for a quote with your deadline and add-ons, or see all plans.
Download the project brief (PDF)
Summary, working, components and cost and viva questions on one branded PDF to show your guide or team. To get it developed, contact us on WhatsApp.
What you submit with this project
- Working model with circuit diagram and program code
- Project report or black book in your university's chapter order (block diagram, circuit, calculations, results)
- Presentation for the review and final viva
- Synopsis for topic approval, if your college asks for one
Mechanical viva questions on this project
What is the aim of the PLC Operated Color Based Product Sorting Machine project?
A PLC-controlled sorting line that separates products by colour. Colour sensors identify each item on the conveyor, and two pneumatic cylinders operated by solenoid valves push it into the matching collection bin.
Explain the working of your project in short.
The mild steel frame and fabrication forms the base that carries every other part, so it is designed first from the load and size of the machine. The DC geared motor provides the driving motion. Motion is transmitted through DC geared motor, pulleys and V-belt, shafts and ball bearings with housing, which set the speed, torque and direction at the working end. The Valves control the direction and flow of air or fluid.
Why is a PLC preferred over a microcontroller in industry?
A PLC is rugged, works on 24 V industrial signals, tolerates noise and heat, and is programmed in ladder logic that maintenance staff understand. It is also easy to modify on site.
How does the TCS3200 detect colour?
It has photodiodes with red, green, blue and clear filters. It outputs a square wave whose frequency depends on the light intensity for the selected filter.
Why is a pull-up resistor needed with a push button?
Without it the input pin floats and reads random values. The pull-up keeps it HIGH until the button connects it to ground.
Why is a relay used?
It electrically isolates the 5 V control circuit from the high-voltage load. The controller energises the coil through a transistor, and the contacts switch the load.
Why is a geared motor used?
The gearbox reduces speed and multiplies torque, so a small DC motor can move a vehicle or mechanism smoothly. Torque increases roughly by the gear ratio.
Which material did you select for the main parts and why?
Mild steel (MS) is used for the frame because it is strong, cheap, easy to cut and weld and available everywhere. Shafts are made of EN8 or bright mild steel for strength, and parts that do not carry load can be aluminium or acrylic to reduce weight.
What factor of safety did you take in your design?
A factor of safety of 2 to 3 is taken for static parts and 3 to 5 for parts under shock or fatigue loading. Allowable stress = yield strength ÷ factor of safety, and each part is checked against it.
How did you estimate the cost of the project?
The cost is the sum of raw material, bought-out parts, machining or fabrication and overheads. Our estimate for this model is about ₹17,500 to ₹25,800, depending on size, material and the workshop rates in your city.
Which manufacturing processes were used?
Cutting and grinding of sections, arc or MIG welding of the frame, drilling for mounting holes, turning of the shafts and fitting of bearings and the drive, followed by assembly, alignment and painting.
Is your system open-loop or closed-loop?
Closed-loop: sensors measure the actual position, distance or condition and the controller corrects the actuators until the target is reached.
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