1
Product behavior
Define viscosity or rheology at filling temperature, foaming, air entrainment, particulates, shear sensitivity and cleanability.
HIJ-DZA100 · plastic syringe fill-and-cap platform
Prefilled Plastic Syringe Filling Machine
Configure automatic syringe loading, ceramic-pump filling, cap feeding, servo capping and discharge around the real product, plastic syringe and cap.
01Use production syringe and cap samples to define the format parts.
02Match the ceramic pump and filling profile to the dose and product behavior.
03Agree fill accuracy, cap quality, accepted output and FAT evidence before build.
0.5–50 mlPublished plastic syringe size range
1,800–2,100 p/hPublished single-needle capacity
≤±1–2%Published accuracy; verify by product and method
Application fit
Use DZA100 when the process is plastic syringe filling and capping
The technical source lists liquid and ointment products and plastic syringe formats from 0.5 to 50 ml. Final suitability depends on product behavior, pump range, syringe/cap geometry and cleaning requirements.
2
Syringe and cap
Provide barrel, tip, flange and cap drawings plus production samples. Special formats require engineered feeders and fixtures.
3
Acceptance criteria
Agree fill calculation, cap position/retention, leakage or cosmetic checks, reject handling and accepted output.
Send these inputs before engineering
- Representative formulation in sufficient test quantity
- Production plastic syringes and matching caps
- Approved drawings and critical tolerances
- Target dose and full filling range
- Cleaning agents and product-contact compatibility needs
- Approved fill and cap inspection methods
Machine process
Five automated stations from loading to discharge
The published DZA100 process combines syringe sorting/loading, quantitative filling, cap sorting/feeding, servo-controlled capping and finished-product output.
1
Load
A vibrating arrangement sorts and presents the nominated plastic syringe to the machine.
2
Fill
A ceramic plunger pump meters the product through the configured filling path.
3
Feed caps
The cap-feeding system sorts and presents the nominated cap for placement.
4
Cap
Servo-controlled actions complete the defined cap-placement and tightening operation.
5
Discharge
Filled and capped syringes leave the machine for the agreed inspection or downstream step.
FAT rule: run the full sequence with the nominated product, syringe and cap. A water-only setup cannot establish performance for a materially different gel, paste or ointment.
Verified technical data
HIJ-DZA100 published reference specifications
These values come from the available DZA100 technical document. The final quotation must identify the exact syringe, cap, pump range, format parts, utilities and optional equipment.
| Parameter | Published value | Project confirmation |
|---|---|---|
| Applicable materials | Liquid and ointment | Product samples, temperature, viscosity/rheology and cleaning method |
| Plastic syringe range | 0.5–50 ml | Exact barrel/cap drawings, supplier tolerances and format parts |
| Number of filling needles | 1 | Needle and product-path design for the target dose |
| Production capacity | 1,800–2,100 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 site capacity |
| Machine dimensions | 1230 × 850 × 1800 mm | Allow for guarding, optional hood, service and transfer access |
| Equipment weight | 500 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 pump
The source document identifies quantitative filling by ceramic plunger pump. Confirm the correct pump range for every target dose.
PLC/HMI monitoring
Siemens HMI, PLC and servo motor are listed in the general configuration, with real-time station status and fault display.
Modular line connection
The published design can operate standalone or connect with selected handling and downstream equipment.
Format and dosing engineering
Size range does not mean one universal setup
The published 0.5–50 ml range describes platform capability. The ordered machine still needs format-specific syringe/cap tooling and a pump assembly suited to the actual filling range.
1
Format parts
Define the syringe feeder, transfer guides, fixtures and cap-feeding parts for every production component set.
2
Pump range
Large differences in fill volume can require a different ceramic pump assembly. List minimum, nominal and maximum dose.
3
Fill profile
Set needle position, fill speed and cut-off against foaming, stringing, dripping, splashing and air entrainment.
When DZA100 is not the right platform
- Choose DZA200 when verified accepted output requires a two-needle plastic syringe platform.
- Choose GZB100/GZB200 when the component is an SCF glass syringe requiring vacuum stopper placement.
- Use a separate feasibility review when the component, closure or process does not match either published route.
Line and cleanroom boundary
Separate base-machine functions from optional line equipment
The DZA100 source describes a modular machine that can run standalone or connect with other equipment. The final proposal must state every included module and interface.
Automatic syringe supply
Define whether the base loading arrangement is sufficient or whether an upstream syringe elevator/feeder is required.
Product feeding
Confirm tank, level control, mixing/heating, product transfer, hold-up and cleaning boundary for the real formulation.
Local clean-air option
An optional laminar-flow hood is listed. Final airflow, room interface, monitoring and qualification are project-specific.
Rod insertion
Plunger-rod insertion is separate downstream equipment and must be included explicitly when the finished syringe requires it.
Labeling and inspection
Define label format, print/vision checks, reject handling and data requirements as a separate scope.
Secondary packaging
Syringe blister packing and cartoning are downstream systems with their own formats, materials, inspection and FAT criteria.
Validation boundary: HIJ can engineer equipment and documentation to support the customer’s qualification project. The installed validated state depends on the facility, environment, components, procedures and site execution.
URS and FAT evidence
Turn the quotation into a testable project scope
Define what must be demonstrated with production components before the machine build and FAT protocol are approved.
Required RFQ/URS inputs
- Product and filling temperature
- Minimum, nominal and maximum dose
- Syringe and cap drawings plus samples
- All production formats and change parts
- Required accepted output
- Fill-accuracy and cap-quality methods
- Utilities and cleanroom interface
- Documentation and downstream boundary
Minimum FAT evidence
- Nominated product, syringe and cap
- Repeat fill study by the approved method
- 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
Output rule: specify accepted syringes per hour after rejects and planned checks—not only mechanical cycle rate.
Frequently asked questions
Prefilled plastic syringe filling machine FAQ
Answers are limited to the published HIJ-DZA100 technical document and the project inputs that still require confirmation.
What does the HIJ-DZA100 automate?
The published process includes plastic syringe loading, ceramic-pump filling, cap sorting/feeding, servo-controlled capping and finished-product output. Optional upstream or downstream equipment must be defined separately.
What syringe sizes can the DZA100 handle?
The published platform range is 0.5–50 ml. This is not one universal setup: provide every syringe and cap drawing because format parts and the pump assembly must match the ordered sizes and fill range.
What is the published output of the DZA100?
The technical document lists 1,800–2,100 units per hour with one filling needle. Actual accepted output depends on product behavior, dose, format, cap 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 and start-up treatment, then verify the result with the actual product during FAT.
Can DZA100 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 product samples, filling temperature, rheology, pump range, cut-off behavior and cleaning requirements.
Can one DZA100 run several syringe formats?
Multiple formats can be engineered, but each syringe/cap set may need dedicated feeders, guides, fixtures and change parts. Large dose differences may also require another ceramic pump assembly.
Can DZA100 connect to a full line?
Yes. The technical source describes modular standalone or connected-line use. Syringe feeding, rod insertion, labeling, inspection, blister packaging and cartoning must each be included and tested as explicit line scopes.
What should be sent for an accurate quotation?
Send the formulation, filling temperature, dose range, syringe and cap drawings, samples, all formats, accepted output, fill/cap acceptance methods, utilities, cleanroom interface and required documentation.
Project inquiry
Configure DZA100 around your product, syringe and cap
Share production samples and acceptance criteria. HIJ can return an itemized machine configuration, format-part list, option boundary and FAT scope.