Filling lines are too complex to allow realistic models of them to be evaluated analytically. In this paper, the requirements for designing filling lines are analysed, and a directed graphbased modelling formalism which unifies object oriented analysis methods, and the 3D geometry and mechanism required for the simulation is proposed. A framework of a virtual simulation system is proposed, and the architecture and main modules of the prototyping tool are introduced. These provide an integrated tool for the design and optimisation of filling lines. Entire facilities and filling line can be modelled in the modelling and simulation environment to evaluate alternatives, and to identify physical bottlenecks. An example is given.