Automatic Gate & Flash Removal Machine for Automotive Molded Gaskets

Custom Automation for Center Gate and Outer Flash Removal

TIMEAST developed this custom automation system for an automotive molded gasket that

 requires both the center molding gate and surrounding outer flash to be removed after molding.

Instead of handling trimming as a separate manual process, the machine combines automatic feeding, 

part orientation,4-piece transfer, rotary indexing, part clamping, gate and flash removal, scrap collection

and finished-part unloading into one continuous process.The system is designed for a production capacity

of up to 2,000 pcs/hour.

Customer Requirement: Automating the Trimming Process

The molded gasket comes out of the molding process with a center gate and excess material around

the outer edge.Both areas must be removed before the finished gasket can move to the next production stage.

The customer wanted to replace manual handling with an automated process capable of continuously feeding, 

positioning and trimming the molded parts while maintaining stable production.

The challenge was therefore not only how to remove the gate and flash.

The feeding direction, part orientation, gripping position, trimming direction, waste separation, transfer method

 and production speed all had to be considered as part of one automation system.

From Molded Part to Finished Gasket

The molded part enters the machine with the center gate and surrounding flash still attached.

During the automatic trimming process, the gasket is held in a controlled position while separate

mechanisms remove the center gate and outer excess material.

The finished gasket is then automatically transferred to the discharge conveyor.

Our Custom Automation Solution

For this project, TIMEAST designed a complete automatic handling and trimming system rather than only 

a standalone cutting station.

The machine integrates an elevator hopper, vibratory bowl feeder, intermediate sliding transfer station, 

4-piece grippers, multi-station rotary indexing table, custom trimming mechanisms, waste collection system 

and finished-part conveyor.

Each part of the machine was designed around the actual gasket structure and production process.

Four parts are transferred together between key stations, while loading, trimming and unloading operations 

are performed at different rotary-table positions.

This allows multiple operations to run in parallel and reduces unnecessary waiting between individual steps.

How the Automatic Gate and Flash Removal Machine Works

1. Elevator Hopper Feeding

Molded gaskets are loaded into the elevator hopper.

The lifting system automatically supplies parts to the vibratory bowl feeder, reducing the need

 for frequent manual replenishment.

2. Vibratory Bowl Orientation

The vibratory bowl feeder sorts and orients the molded parts.

Correctly positioned parts are transferred through the feeding track to the defined pickup position.

3. Four-Part Pickup

A pickup gripper collects four parts at the same time from the feeding position.

The four gaskets are placed onto the positioning fixtures of the intermediate sliding station.

4. Sliding Transfer

The slide moves the four parts from the feeding side to the rotary-table loading position.

A second pickup mechanism then collects all four parts from the intermediate station.

5. Loading the Rotary Table

The four gaskets are placed into dedicated fixtures on the multi-station rotary indexing table.

The rotary table indexes to the next working position according to the PLC program.

6. Part Clamping

Before trimming starts, dedicated hold-down clamps move downward and secure the molded gaskets.

Stable positioning is important because the center gate and surrounding flash are removed by controlled 

mechanical movement.

7. Center Gate Removal

The upper rotating gripper grips the center molding gate.

The gripping and pulling movement is controlled according to the product structure so that the center gate 

can be separated from the gasket.

8. Outer Flash Removal

A lower gripping mechanism engages the outer excess material.

The machine combines controlled gripping, rotation and pulling with blade-assisted cutting to separate

 the outer flash from the finished gasket.

9. Scrap Collection

Removed center gates and flash are separated from the finished parts.

The waste material is released into a dedicated scrap collection bin located inside the lower machine frame.

10. Finished-Part Unloading

After trimming is completed, the rotary table indexes to the unloading station.

The unloading gripper picks the finished gaskets from the rotary fixtures and places them onto the discharge

conveyor.

11. Transfer to the Next Process

The conveyor transfers the finished parts to a collection container or directly to the customer's next 

production process.All stations operate according to the programmed PLC sequence to complete 

one continuous automatic production cycle.

See the Automatic Gate & Flash Removal Process in Action

Watch the complete process from automatic feeding and 4-piece transfer to gate and flash removal, 

scrap collection and finished-part unloading.

Why We Used a Multi-Station Rotary System

The required production capacity could not be achieved efficiently by performing feeding, trimming

and unloading one operation at a time.

For this reason, the system uses a multi-station rotary indexing table combined with 4-piece handling.

While one group of parts is being trimmed, another station can perform loading or unloading.

This overlap between stations reduces idle time and allows the machine to reach a production capacity of:

Up to 2,000 pcs/hour

The rotary layout also provides dedicated positions for loading, trimming and unloading, making it easier

to control part positioning and coordinate the different mechanisms.

Custom-Designed Gate and Flash Removal Mechanism

The trimming mechanism was developed specifically for the structure of this molded gasket.

The machine does not rely on only one blade to cut the excess material.

Instead, the process combines: 

part clamping + center gate gripping + outer flash gripping + controlled rotation + 

pulling + blade-assisted cutting

This allows the unwanted molding material to be removed automatically while the finished

gasket remains securely positioned.

The gripping method, trimming direction, fixture design and cutting mechanism can be changed 

for other products according to the actual: gate position, flash structure, product geometry, 

material and required trimming result.

This is one of the key differences between a standard trimming machine and a custom automation system.

PLC-Controlled Multi-Station Operation

The complete production sequence is coordinated through the PLC.

The control system manages the elevator hopper, vibratory feeder, transfer slides, pneumatic cylinders, 

grippers, rotary table, trimming mechanisms, sensors, scrap discharge and finished-part conveyor.

The HMI allows the operator to run the machine, monitor operating status and handle machine alarms

from one interface.The different mechanisms are programmed to work together instead of completing 

each process as an isolated movement.

This coordination is especially important in a multi-station machine where feeding, loading, trimming 

and unloading may occur at the same time.

Electrical and Pneumatic Components

The electrical and pneumatic configuration was selected according to the customer's equipment 

requirements.

Using established industrial components also makes replacement parts, maintenance and 

troubleshooting easier for the customer's production team.

Component brands can be adjusted for other automation projects according to the

 customer's approved supplier list or factory standard.

Machine Safety and Interlock Design

Operator safety is integrated into the machine design.

The system is equipped with an emergency stop, three-color warning light, safety light curtain and

safety-door interlock.

If the safety door is opened or the light curtain is interrupted during operation, the corresponding 

machine operation is stopped according to the safety control logic.

The machine enclosure and frame were finished in RAL 9002, according to the customer's requested 

equipment color specification.

What Was Customized for This Project?

This machine was not built by simply adding a trimming mechanism to a standard platform.

The automation layout was developed around the customer's actual molded gasket, trimming 

requirements and production target.

For this project, TIMEAST customized the feeding method, bowl feeder tooling, 4-piece pickup 

mechanism, intermediate transfer station, rotary-table fixtures, part hold-down system, center gate gripper,

outer flash removal mechanism, cutting tooling, waste collection system, unloading mechanism, 

PLC sequence and safety configuration.

The result is not simply a gate removal station.It is a complete automatic process covering:

bulk part feeding → orientation → positioning → trimming → scrap separation → finished-part unloading

This type of project is also a good example of how we approach custom automation: the equipment is designed 

around the customer's product and production process rather than forcing the product into a fixed standard machine.

Can This Automation Be Used for Other Molded Parts?

Yes.

The machine shown in this case was developed specifically for an automotive molded gasket, 

but the same automation approaccan be applied to other molded plastic or elastomer components 

requiring automatic post-molding processing.

Depending on the product, the system can be designed for:

automatic gate removal, degating, flash removal, trimming, part separation, orientation,

 inspection, assembly and downstream transfer.

The final machine structure does not need to be identical to this project.

The feeding system, grippers, fixtures, trimming mechanism, number of parts handled per cycle 

and downstream process can all be designed according to the actual application.

Typical Information We Need for a Similar Automation Project

To evaluate an automatic gate or flash removal application, we normally need the customer's part samples or drawings, 

material information, gate and flash condition, current trimming method, required production capacity and downstream 

production process.

A video showing the current manual operation is also useful because it helps our engineers understand how the unwanted 

material is currently separated from the finished part.

Based on this information, we can evaluate the feeding method, positioning, gripping, trimming process and overall 

automation concept.

Frequently Asked Questions

Can the machine remove both the center gate and outer flash?

Yes. In this project, separate mechanisms are used to handle the center gate and surrounding flash. 

The final removal method combines gripping, pulling, rotation and blade-assisted cutting.

Is 2,000 pcs/hour the output for every product?

No. The achievable production capacity depends on the product structure, feeding stability, trimming method, 

number of parts handled at one time and any additional inspection or downstream processes.

For this automotive gasket project, the system was designed for an output of up to 2,000 pcs/hour.

Can you automate products with a different gate or flash structure?

Yes. The trimming mechanism is designed according to the actual molded part. The gripping position, 

pulling direction, cutting method and fixtures can be changed for different products.

Can the finished parts be transferred directly to another machine?

Yes. The discharge conveyor can transfer finished products to a collection bin or connect with 

downstream assembly, inspection, marking or packaging equipment.

Can we specify the PLC and pneumatic component brands?

Yes. Components can be selected according to the customer's factory standard or approved supplier list.

For this project, Mitsubishi, SMC, Schneider Electric and Omron components were used according to 

the specified configuration.

What do you need before designing a custom trimming machine?

Part samples or drawings are the most useful starting point. We also recommend providing the part material, 

gate and flash details, current trimming process, required production capacity and any downstream process 

requirements.

Have a Similar Gate or Flash Removal Project?

If your molded parts still require manual gate removal, flash trimming or part separation after molding, 

send us the actual product information.

Our engineering team can evaluate the complete process from feeding and positioning to trimming and

finished-part transfer.

Please send us:

part samples or drawings, photos of the gate and flash, material information, current process video and

required production capacity.

Discuss Your Automation Project

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Engineering Support:engineering@sztimeast.com