HIJ-DZA100
Plastic Syringe Filling & Capping
1 needle1,800–2,100 p/h
For liquid or ointment products in plastic syringes. The published size range is 0.5–50 ml.
Four verified platforms · one selection path
Pre-filled Syringe Filling Machines
Select a syringe filling machine by the actual barrel, closure method, product behavior, output target and FAT acceptance criteria—not by one headline speed.
01Plastic syringe filling and capping: HIJ-DZA100 or HIJ-DZA200.
02SCF glass syringe vacuum filling and plugging: HIJ-GZB100 or HIJ-GZB200.
03Single- or double-needle configuration based on accepted output and process evidence.
4 platformsPlastic capping and glass vacuum-plugging routes
1 or 2 needlesPublished single- and double-needle configurations
≤±1–2%Published accuracy; verify by product and test method
Model range
Choose the platform that matches the syringe and closure
Each machine below has a separate technical source. Published capacity is a reference, not a guaranteed accepted output; the real product, syringe, closure and inspection method must be tested.
HIJ-DZA200
Double-Head Plastic Syringe Filler
2 needles3,000–3,900 p/h
Higher published output for plastic syringe filling and capping. The published size range is 1–50 ml.
HIJ-GZB100
Vacuum Filling & Plugging
1 needle600–800 p/h
For nominated SCF glass syringes and vacuum stopper placement. Published sizes are format-specific.
HIJ-GZB200
Double-Head Vacuum Filler
2 needles800–1,200 p/h
Two-needle vacuum filling and plugging for nominated SCF glass syringe formats.
Verified comparison
Compare the four syringe filling machine platforms
Use this table to shortlist a machine. Final scope still depends on component drawings, product samples, format parts, dosing method and the agreed FAT protocol.
| Model | Closure route | Published sizes | Needles | Published capacity | Power |
|---|---|---|---|---|---|
| HIJ-DZA100 | Plastic syringe filling and capping | 0.5–50 ml | 1 | 1,800–2,100 p/h | 3 kW |
| HIJ-DZA200 | Plastic syringe filling and capping | 1–50 ml; format and pump changes may be required | 2 | 3,000–3,900 p/h | 8.5 kW |
| HIJ-GZB100 | SCF glass syringe vacuum filling and plugging | 0.5, 1, 2.25, 3, 5, 10, 20 ml; not universal | 1 | 600–800 p/h | 2.5 kW |
| HIJ-GZB200 | SCF glass syringe vacuum filling and plugging | 0.5, 1, 2.25, 3, 5, 10, 20 ml; not universal | 2 | 800–1,200 p/h | 3 kW |
Accuracy reference: all four source documents publish ≤±1–2%. Define whether acceptance is by mass or volume, the sample count, product temperature, start-up treatment and calculation method before using that value in a URS.
Selection route
Start with the syringe system—not the machine name
Plastic capping and SCF glass vacuum plugging are different process paths. Define the component set first, then select the number of filling needles.
DZA100 or DZA200
Use when the required process is quantitative filling followed by cap feeding and capping for a plastic syringe format.
- Confirm syringe and cap geometry
- Confirm liquid or ointment behavior
- Choose one or two filling needles
- Define capping quality and reject criteria
- List every included format and pump range
GZB100 or GZB200
Use when the nominated SCF syringe and stopper require vacuum-assisted filling and vacuum stopper placement.
- Confirm tub/nest, syringe and stopper supplier
- Define viscosity and visible-air limit
- Choose one or two filling needles
- Define stopper-position acceptance
- Identify manual or automatic denesting scope
Do not specify “bubble-free” as an undefined promise. Set a visible-air inspection method, defect limit, product condition and sample quantity, then demonstrate the result with the actual formulation during FAT.
Engineering inputs
Five decisions determine the real filling system
A useful quotation separates machine platform, format parts, product path, optional modules, documentation and acceptance evidence.
1
Product
Composition, viscosity/rheology, temperature, particulates, foaming, air release and cleaning compatibility.
2
Component
Syringe, tub/nest, cap or stopper drawings, supplier tolerances and production samples.
3
Dose
Target fill, permitted accuracy method, pump range, needle geometry and fill profile.
4
Output
Required accepted units per hour after inspection, reject handling and normal operating losses.
5
Environment
Cleanroom interface, laminar-flow boundary, utilities, access, intervention and documentation scope.
Send production components, not representative photos
- Enough formulation for setup, adjustment and repeat runs
- Production syringe, cap/stopper, tub and nest samples
- Approved drawings with critical tolerances
- Quality methods for fill amount, visible air and closure position
- Required cleaning and material-certificate expectations
Line and cleanroom boundary
Define the base machine, options and downstream scope separately
The four documents describe modular equipment that can operate standalone or connect with additional handling and packaging equipment. Only ordered, engineered and tested modules belong in the final scope.
Infeed and denesting
The GZB route can be configured around manual grouped loading or an optional automatic nest-removal machine. Define tub opening and liner handling separately.
Product supply
Confirm tank, mixing/heating needs, product transfer, hold-up, cleaning and the battery limits between customer utilities and machine.
Closure handling
Plastic cap feeding and glass syringe stopper handling require different parts, feeders and acceptance checks.
Rod insertion and labeling
Plunger-rod insertion and syringe labeling are optional downstream functions, not automatic inclusions in the base filler.
Local clean-air option
Optional laminar-flow hoods are listed in the source documents. Final airflow, room interface, monitoring and qualification remain project-specific.
Secondary packaging
Define inspection, labeling, blister packaging, cartoning and reject tracking as separate connected-line scopes.
Aseptic and validation boundary
HIJ can engineer equipment and documentation to support the customer’s qualification process. The installed validated state depends on the facility, environment, components, procedures, interventions and site execution.
- Define DQ/IQ/OQ/PQ deliverables in the URS
- Agree material certificates and product-contact documentation
- Map alarms, recovery steps and permitted interventions
- Confirm the FAT-to-SAT open-item process
URS and FAT evidence
Convert performance claims into testable acceptance criteria
The same machine can produce different results with a different formulation, component tolerance, pump range or inspection method. Lock the evidence plan before the build.
Required RFQ/URS inputs
- Exact product and filling temperature
- Syringe, cap/stopper and nest/tub drawings
- All production formats and target doses
- Accepted output and batch profile
- Fill-accuracy calculation and sampling plan
- Visible-air and closure-position limits
- Utilities, cleanroom interface and line boundary
- Documentation and language requirements
Minimum FAT evidence
- Nominated product and production components
- Repeat fill study using the approved method
- Visible-air or splash challenge where applicable
- Cap/stopper placement and defect challenge
- Normal run at the agreed operating window
- Alarm, stop, restart and recovery records
- Changeover and cleaning demonstration
- Retained samples and signed open-item list
FAT rule: water-only testing does not establish performance for a materially different production formulation. Use representative product whenever viscosity, foaming, air release, temperature or cleaning behavior affects the process.
Frequently asked questions
Syringe filling machine FAQ
Answers are limited to the verified HIJ-DZA100, DZA200, GZB100 and GZB200 technical documents and the project inputs still required.
What is a pre-filled syringe filling machine?
It is equipment that meters product into a syringe and completes the defined closure step. In this HIJ range, DZA machines fill and cap plastic syringes, while GZB machines fill nominated SCF glass syringes and place the stopper under vacuum.
Which HIJ model is suitable for plastic syringes?
DZA100 is the published one-needle platform at 1,800–2,100 units per hour; DZA200 is the two-needle platform at 3,000–3,900 units per hour. Confirm syringe/cap samples, product, dose and accepted output before selection.
Which HIJ model is suitable for SCF glass syringes?
GZB100 is the published one-needle vacuum filling and plugging platform at 600–800 units per hour; GZB200 uses two needles and lists 800–1,200 units per hour. Both require the exact syringe, stopper and format confirmation.
Is a double-head syringe filler always the better choice?
No. A double-head platform offers higher published capacity, but the correct choice depends on accepted output, dose, product behavior, cleaning, format-change frequency, operator access and the FAT evidence required.
Can one machine run every syringe size?
No universal claim should be made. Source documents state size ranges, but different syringes can require molds, feeders, guides and different ceramic pump assemblies. List every production format in the quotation.
Does vacuum filling guarantee zero visible air?
No universal zero-air guarantee should be offered without a defined method and product trial. Set the visible-air limit, lighting or inspection method, product condition and sample quantity, then demonstrate the result during FAT.
Can the line include denesting, rod insertion and labeling?
Yes, these functions can be engineered as optional modules or connected equipment. They are not automatically included in the base filling machine; define the exact infeed, transfer, inspection, rod-insertion, labeling and discharge boundary.
What should be sent for an accurate quotation?
Send the formulation and filling temperature, target dose, syringe and closure drawings, production samples, all formats, accepted output, accuracy method, visible-air or closure limits, utilities, cleanroom interface and required documentation.
Project inquiry
Get a syringe filling line configured around real samples
Share the product, syringe, cap or stopper, fill range, accepted output, cleanroom interface and FAT criteria. HIJ can return a model comparison and itemized project scope.