1
Product behavior
Define viscosity or rheology at filling temperature, foaming, air entrainment, particulates, stringing, shear sensitivity and product-contact compatibility.
HIJ-DZA200 · two-needle plastic syringe platform
Double-Head Prefilled Plastic Syringe Filling Machine
Configure two-needle filling, automatic syringe loading, cap feeding and servo capping around your real formulation, dose range, plastic syringe and cap.
01Use production syringe and cap samples to define format-specific handling parts.
02Balance both ceramic-pump filling paths against the approved fill method.
03Prove accepted output, fill results and cap quality with the nominated product during FAT.
1–50 mlPublished plastic syringe range
3,000–3,900 p/hPublished two-needle capacity
≤±1–2%Published accuracy; verify by product and method
Application fit
Start with the product, syringe and cap—not the headline speed
The DZA200 technical source lists liquid and ointment products in 1–50 ml plastic syringes. Final suitability depends on product behavior, filling temperature, dose range, component geometry, cleaning boundary and the required inspection method.
2
Syringe and closure
Provide barrel, tip, flange and cap drawings plus production samples. Supplier tolerances and presentation behavior affect every guide and fixture.
3
Accepted output
Specify good syringes per hour after rejects and planned checks, together with the fill, cap, leakage and cosmetic acceptance methods.
Send these inputs before configuration
- Representative formulation and filling temperature
- Minimum, nominal and maximum filling volume
- Production syringes and matching caps
- Approved component drawings and critical tolerances
- Cleaning agents and product-contact requirements
- Target accepted output and inspection methods
- Utilities, room interface and documentation needs
Machine process
Five automated stages from syringe loading to discharge
The DZA200 process combines component presentation, two-needle quantitative filling, cap feeding, controlled capping and finished-syringe output. Each stage must be configured for the nominated syringe and closure.
1
Load
Sort, orient and present the production plastic syringe to the transfer system.
2
Fill two syringes
Two ceramic-plunger pump paths meter product through the configured needles.
3
Feed closures
Sort and present the nominated cap or plug for the next operation.
4
Cap
Complete the defined closure-placement and tightening sequence under controlled motion.
5
Discharge
Transfer filled and capped syringes to the agreed inspection or downstream process.
FAT rule: test the full sequence with the nominated formulation, syringe and cap. A water-only run cannot establish performance for a materially different gel, paste or ointment.
Verified technical data
HIJ-DZA200 published reference specifications
These values come from the available DZA200 technical document. The final quotation still needs the exact product, dose range, syringe/cap set, pump configuration, format parts, utilities and optional modules.
| Parameter | Published value | Project confirmation |
|---|---|---|
| Applicable materials | Liquid and ointment | Product samples, filling temperature, rheology and cleaning method |
| Plastic syringe range | 1–50 ml | Exact barrel/cap drawings, tolerances and format parts |
| Number of filling needles | 2 | Needle geometry, spacing and product path for the target dose |
| Production capacity | 3,000–3,900 units/hour | Verify accepted output with actual product and inspection criteria |
| Filling accuracy | ≤±1–2% | Define method, sample count, temperature and calculation |
| Total power | 8.5 kW | Confirm ordered voltage: 380 V or 220 V, 50–60 Hz |
| Compressed air | 0.55–0.75 MPa; 20 L/s | Confirm air quality, connection and available site capacity |
| Machine dimensions | 3200 × 1460 × 1970 mm | Allow for guarding, service, optional hood and line transfer |
| Equipment weight | 900 kg | Confirm floor loading, moving route and installation plan |
| Construction | SUS 304 exterior; SUS 316L and medical silicone product-contact parts | Confirm certificates, surface and chemical compatibility requirements |
Ceramic plunger pumps
The source identifies quantitative filling by ceramic plunger pump. Confirm the pump range and balancing method for every target dose.
PLC/HMI and servo control
Siemens HMI, PLC and servo are listed in the general configuration for operation, monitoring and fault display.
Modular line connection
The published design can operate standalone or connect to selected upstream and downstream equipment.
Two-head filling engineering
Two needles add capacity only when both filling paths remain controlled
The DZA200 is not simply a faster copy of a single-head machine. Pump selection, needle geometry, product supply and the acceptance method must support repeatable results from both filling positions.
1
Match pump range to dose
Large filling-volume differences can require a different pump assembly. List minimum, nominal and maximum dose for every format.
2
Balance both channels
Define how results from filling head A and head B will be sampled, calculated, compared and adjusted during setup and FAT.
3
Control the product feed
Tank level, temperature, mixing, product transfer and hold-up can affect delivery to both pumps and must be included in the process boundary.
Format-change checklist
- Syringe feeder and transfer guides for every barrel format
- Cap feeder, track and placement parts for each closure
- Needle spacing, insertion position and cut-off profile
- Pump assembly and calibration range for each dose family
- Changeover sequence, line clearance and recipe control
- First-off inspection before released production
Line and room boundary
Separate the base machine from optional feeding and downstream modules
The DZA200 source describes a modular platform. The final proposal must identify which module supplies syringes and product, where inspection occurs and who owns every mechanical, electrical and data interface.
Syringe supply
Define whether the base loading arrangement is sufficient or an upstream syringe elevator and automatic material-feeding system are required.
Product feeding
Confirm tank, level control, optional agitation or heating, product transfer, hold-up and cleanability for the real formulation.
Local clean-air option
An optional laminar-flow hood is listed. Airflow, monitoring, room interface and qualification scope remain project-specific.
Rod insertion and labeling
Plunger-rod insertion and automatic syringe labeling are separate downstream scopes and must be included explicitly when required.
Inspection and rejection
Define fill, closure, print and vision checks together with reject confirmation, sample handling and required records.
Secondary packaging
Syringe blister packing and cartoning have their own formats, materials, inspection points and FAT criteria.
Qualification boundary: HIJ can engineer equipment and documentation to support the customer’s qualification project. The installed qualified state depends on the facility, environment, components, procedures and site execution.
URS and FAT evidence
Convert a machine quotation into a testable DZA200 project scope
Write the product, format, accepted output and quality methods into the URS before approving the configuration. Then use the same inputs to build the FAT protocol.
Required RFQ/URS inputs
- Formulation and filling temperature
- Minimum, nominal and maximum dose
- Syringe and cap drawings plus production samples
- All formats and required change parts
- Required accepted output
- Fill and cap acceptance methods
- Utilities and room interface
- Documentation and downstream boundary
Minimum FAT evidence
- Nominated product, syringe and cap
- Separate and combined results from both filling heads
- Cap placement, retention and defect challenge
- Normal run at the agreed operating window
- Alarm, stop, restart and recovery records
- Changeover and cleaning demonstration
- Reject path and downstream-transfer checks
- Retained samples and signed open-item list
Evidence rule: report accepted syringes per hour after rejects and planned checks. Mechanical cycle rate alone does not prove usable production output.
Frequently asked questions
Double-head prefilled plastic syringe filling machine FAQ
Answers below separate published DZA200 reference data from the product- and format-specific points that still require engineering confirmation.
What does the HIJ-DZA200 automate?
The published process covers plastic syringe loading, two-needle ceramic-pump filling, cap or plug feeding, controlled capping and finished-product output. Optional upstream and downstream modules must be listed separately.
What syringe sizes can the DZA200 handle?
The published platform range is 1–50 ml. This is not one universal setup: each production syringe and cap set may require dedicated feeders, guides, fixtures and other format parts.
What is the published output of the DZA200?
The technical document lists 3,000–3,900 units per hour with two filling needles. Actual accepted output depends on the product, dose, format, closure process and inspection criteria.
What filling accuracy is published?
The source lists ≤±1–2%. Define whether testing is by mass or volume, the sample count, product temperature, calculation, startup treatment and how the two filling heads will be compared.
Can the DZA200 fill gels, pastes or ointments?
The source lists liquid and ointment products. Suitability for a specific gel, paste or viscous product must be confirmed from representative samples, filling temperature, rheology, pump range, cut-off behavior and cleaning requirements.
Can one DZA200 run several syringe formats?
Multiple formats can be engineered, but each syringe and cap set may require dedicated feeders, guides, fixtures and change parts. Large dose differences can also require another filling-pump assembly.
How should both filling heads be tested?
Use the approved fill method to record results from head A and head B separately as well as together. Agree sample size, calculation, limits, adjustment method and test conditions before FAT.
What should be sent for an accurate quotation?
Send the formulation, filling temperature, dose range, syringe and cap drawings, production samples, all formats, accepted output, fill and cap acceptance methods, utilities, room interface and required documentation.
Project inquiry
Configure DZA200 around your formulation, syringe and cap
Share production samples and acceptance criteria. HIJ can return an itemized machine configuration, format-part list, option boundary and FAT scope.