1
Formulation
Define viscosity or rheology at filling temperature, foaming, air entrainment, shear sensitivity, particulates and product-contact compatibility.
HIJ-GZB200 · two-needle SCF syringe platform
Double-Head Prefilled Syringe Vacuum Filling Machine
Configure dual-head vacuum filling and vacuum stoppering around the real formulation, dose, SCF syringe nest, stopper and acceptance method.
01Confirm the production syringe, nest/tub and stopper before format engineering.
02Match both ceramic-pump paths and the vacuum process to the actual product.
03Prove fill results, stopper position and accepted output during FAT.
2 filling needlesPublished double-head platform
800–1,200 p/hPublished reference capacity
±1–2%Published accuracy; verify by product and method
Application fit
Use GZB200 for SCF glass-syringe filling and vacuum stoppering
The technical source lists liquid and ointment materials and common SCF syringe formats. Final suitability depends on formulation behavior, dose, syringe/nest presentation, stopper geometry, vacuum response, cleaning boundary and the approved inspection method.
2
SCF component set
Provide the syringe, nest/tub, stopper and any lid or liner drawings plus production samples. Format compatibility cannot be inferred from nominal volume alone.
3
Acceptance method
Specify good syringes per hour together with fill calculation, stopper depth/position, trapped-air or void inspection and reject criteria.
Published syringe compatibility still requires samples
The source lists SCF syringes from BD, BG, SCHOTT and major domestic manufacturers, with other syringe types available for customization. Confirm the actual component set rather than relying only on the supplier name.
- Production formulation and filling temperature
- Minimum, nominal and maximum dose
- Production syringe, nest/tub and stopper
- Drawings, tolerances and all required formats
- Vacuum-process and trapped-air acceptance method
- Utilities, room interface and documentation needs
Configured process boundary
Six stages from optional nest handling to filled-syringe discharge
Specify which handling steps are included in the quoted line. Automatic nest removal and syringe feeding are optional modules in the technical source, while filling and stoppering are the core GZB200 operations.
1
Remove nest cover
When included, the optional nest-removal module prepares the nominated syringe nest/tub for automatic feeding.
2
Present syringes
Transfer the SCF syringe set into the configured loading and positioning sequence without damaging the components.
3
Vacuum fill
Two ceramic-pump paths fill the nominated dose; needle movement with the liquid level is listed to reduce splashing risk.
4
Feed stoppers
Present the approved stopper to the stoppering station with the required orientation and handling method.
5
Vacuum stopper
Apply the configured vacuum stoppering sequence and confirm stopper position, contact and defect criteria.
6
Discharge
Transfer accepted syringes to the agreed inspection, rod insertion, labeling or packaging step.
FAT rule: test the complete quoted sequence with the nominated formulation, syringe/nest and stopper. A water-only run cannot establish performance for a materially different viscous product.
Verified technical data
HIJ-GZB200 published reference specifications
These values come from the available GZB200 technical document. The final proposal must identify the exact product, syringe/nest, stopper, pump range, format parts, vacuum boundary, utilities and optional modules.
| Parameter | Published value | Project confirmation |
|---|---|---|
| Applicable materials | Liquid and ointment | Samples, filling temperature, rheology and cleaning method |
| Published syringe sizes | 0.5, 1, 2.25, 3, 5, 10 and 20 ml; not universal | Exact syringe/nest/stopper drawings, tolerances and format parts |
| Number of filling needles | 2 | Needle geometry and pump range for the target dose |
| Production capacity | 800–1,200 units/hour | Verify accepted output with actual product and inspection criteria |
| Filling accuracy | ±1–2% | Define method, sample count, temperature and calculation |
| Total power | 3 kW | Confirm ordered voltage: 380 V or 220 V, 50–60 Hz |
| Compressed air | 0.55–0.75 MPa; 15 L/s | Confirm air quality, connection and available capacity |
| Vacuum system | 6 × 10⁻² Pa; 20 L/s | Confirm pump arrangement and acceptance test conditions |
| Machine dimensions | 1020 × 840 × 1730 mm | Allow for service, optional hood and line transfer |
| Equipment weight | 400 kg | Confirm floor loading, moving route and installation plan |
| Construction | AISI 304 exterior; AISI 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 each target dose.
PLC/HMI and servo control
Siemens HMI, PLC and servo motors are listed in the standard configuration for operation and synchronous actions.
Fill and stopper process
The vacuum sequence is intended to reduce trapped-air, void and stopper-friction risks. Verify the actual result with product and components.
Vacuum-process engineering
Define what “low trapped air” means before selecting the machine
A vacuum system is a process tool, not an automatic guarantee. Product viscosity, dissolved gas, temperature, fill path, vacuum level, hold time, syringe geometry and inspection sensitivity all affect the final result.
1
Set the product condition
Specify filling temperature, preconditioning, mixing, hold time and whether a separate material-defoaming vessel is required.
2
Balance both filling heads
Record results from head A and head B separately and together using the approved mass- or volume-based method.
3
Define the inspection limit
Agree how trapped air, visible voids, stopper contact, fill result and cosmetic defects will be measured and accepted.
Format and pump decisions
- Dedicated format parts for each syringe/nest/stopper set
- Pump and ceramic-valve range matched to each dose family
- Separate product-contact arrangement where material compatibility requires it
- Needle position and fill profile matched to product behavior
- Vacuum settings protected by controlled recipes
- First-off and changeover verification before released production
Line and room boundary
Separate core filling from optional nest handling and downstream equipment
The final quotation should name every included module, interface and responsibility. Optional equipment changes the physical layout, room interface, controls and FAT scope.
Automatic nest remover
The source lists an optional module to remove syringes from the nest box and feed them automatically. Confirm the exact nest/tub and lid presentation.
Material feed and defoaming
Define tank size, level control, transfer, optional agitation/heating and whether a separate 15 L defoaming vessel is included.
Local laminar-flow hood
An optional laminar-flow hood is listed. Airflow, monitoring, room interface and qualification remain project-specific.
Automatic rod insertion
An optional syringe rotating-rod machine and rod-detection function are listed. Include them explicitly when the finished device requires a rod.
Inspection and rejection
Define fill, stopper, rod and print/vision checks with reject confirmation, sample handling and required data records.
Secondary packaging
Prefilled-syringe blister packing and cartoning have separate materials, formats, 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 GZB200 quotation into a testable project scope
Use the same approved product, component and quality inputs in the URS, engineering review and FAT protocol so the result can be evaluated consistently.
Required RFQ/URS inputs
- Formulation and filling temperature
- Minimum, nominal and maximum dose
- Syringe, nest/tub and stopper samples
- All formats and required change parts
- Required accepted output
- Fill, trapped-air and stopper methods
- Utilities and room interface
- Documentation and downstream boundary
Minimum FAT evidence
- Nominated product and full component set
- Separate and combined results from both filling heads
- Vacuum-setting and trapped-air/void evaluation
- Stopper position, contact and defect challenge
- Normal run at the agreed operating window
- Alarm, stop, restart and recovery records
- Changeover, cleaning and reject-path 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 syringe vacuum filling machine FAQ
These answers separate published GZB200 reference data from the product- and component-specific points that still require engineering confirmation.
What does the HIJ-GZB200 automate?
The core published process is two-needle filling and stoppering for prefilled glass syringes. Automatic nest removal, syringe feeding, rod insertion and other downstream equipment are optional modules that must be listed separately.
Which syringe sizes are listed for the GZB200?
The technical source lists 0.5, 1, 2.25, 3, 5, 10 and 20 ml formats and states that they are not universal. Each production syringe, nest/tub and stopper set must be checked and configured.
What is the published output of the GZB200?
The technical document lists 800–1,200 units per hour with two filling needles. Actual accepted output depends on product behavior, dose, component format, vacuum/stoppering 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 results from both filling heads will be compared.
Does vacuum filling guarantee bubble-free syringes?
No machine label alone can guarantee that result. The vacuum process is intended to reduce trapped-air and void risks, but formulation condition, dissolved gas, temperature, settings, syringe geometry and the inspection method must be tested with representative samples.
Can GZB200 process viscous products or ointments?
The source lists liquid and ointment materials and identifies vacuum filling as suitable for viscous materials. Suitability still requires samples, filling-temperature and rheology data, pump-range review, vacuum trials and a cleaning plan.
Is automatic syringe denesting included?
The source lists an automatic nest remover as optional equipment. The quotation must state whether nest removal, syringe feeding, lid handling and their room/line interfaces are included.
What should be sent for an accurate quotation?
Send the formulation, filling temperature, dose range, syringe/nest/stopper drawings and samples, every format, accepted output, fill/trapped-air/stopper acceptance methods, utilities, room interface and required documentation.
Project inquiry
Configure GZB200 around your formulation and SCF components
Share production samples and acceptance criteria. HIJ can return an itemized machine configuration, optional-module boundary, format-part list and FAT scope.