Tailored wastewater treatment systems engineered to your exact flow, load and chemistry — designed, built and commissioned around your site, never an off-the-shelf package.
Custom automation and SCADA integration for critical water treatment processes plants.
Seamlessly integrate new water treatment equipment with your existing infrastructure.
Complete turnkey water treatment plants from initial concept through commissioning.
Comprehensive support packages including preventive maintenance, remote diagnostics, operator training and genuine spare parts.
At Reynolds Bauhm, we understand that no two industrial processes are identical–and neither should their wastewater treatment systems be. While standard, off-the-shelf equipment may offer quick fixes, they rarely deliver the long-term efficiency, compliance, and operational integration that modern industrial facilities demand.
Our bespoke solutions bridge this gap, offering custom-designed wastewater treatment architectures that are engineered specifically around your process parameters, site constraints, production variables, and regulatory requirements.
Industrial wastewater composition varies dramatically across sectors. A dairy processor faces entirely different challenges–high BOD, fats, oils, and variable flow rates–than a brewery managing yeast and hop residues, or a chemical manufacturer handling complex effluent streams.
Off-the-rack systems force your process to adapt to the equipment. Our bespoke approach inverts this relationship: we design the equipment to adapt seamlessly to your process. This means:
True bespoke solutions begin with process design, not equipment selection. Our engineering team employs a staged approach that treats your wastewater challenge as a unique chemical and hydraulic puzzle:
We begin with comprehensive effluent analysis — COD, BOD, TSS, TKN, pH variability, temperature profiles, and flow dynamics. Using this data, we build process flow diagrams (PFDs) and mass balance models specific to your waste streams.
Not every application requires the same Treatment Process. Our independence as an equipment manufacturer allows us to select the optimal technology combination without bias. This might mean:
We model your complete system using CFD (Computational Fluid Dynamics) where necessary, ensuring optimal flow distribution, retention times, and sludge handling characteristics. Our comprehensive design services include 3D CAD modelling, mechanical engineering, and full manufacturing documentation.
Dissolved Air Flotation forms the backbone of many of our bespoke solutions, particularly for food & beverage, dairy, and industrial applications where rapid solids removal and FOG (Fats, Oils, and Grease) separation are critical.
Rather than offering a single"standard" DAF unit, we engineer multiple configurations tailored to specific process demands:
Integrated flocculation and coagulation zones with variable-speed mixing, automated chemical dosing, and reaction tank retention times calculated for your specific contaminant profile. Ideal for dairy waste with high protein loads or industrial effluent requiring metal precipitation.
Explore Custom EngineeringStreamlined configurations for applications where minimal chemical intervention is preferred, focusing instead on air-to-solids ratios and pressure vessel optimisation for primary solids separation.
Explore Custom EngineeringIntegrated automation solutions for critical water treatment processes systems.
Discover MoreEngineered solutions with defined performance targets and warranties.
Discover MoreCompact units engineered for space-constrained sites, featuring lamella plate separation and enhanced bubble generation systems to achieve equivalent treatment capacity in 40% less footprint than conventional designs.
Space-Constrained SolutionsSpecialised configurations optimised not just for effluent treatment but for sludge volume reduction–critical for sites where downstream sludge handling costs (transport, disposal, or further dewatering to spadable consistency) dominate operational expenditure.
Explore Custom EngineeringEach DAF unit is sized based on your actual hydraulic and solids loading, not generic"m³/day" categories. We calculate air dissolution rates, rise velocities, and surface loading rates specific to your waste characteristics.
When existing treatment plants face capacity constraints, regulatory changes, or aging infrastructure, greenfield construction isn't always the answer. Our upgrade and retrofit solutions modernise your existing facilities with efficient enhancements.
Extend the life and improve performance of existing treatment plants through strategic equipment upgrades, process modifications, and automation enhancements. Retrofit projects typically cost 30-50% less than new construction while delivering comparable performance improvements.
Plant Upgrade SolutionsIncrease plant throughput through hydraulic and process improvements without major civil works. Parallel process trains, high-rate clarification, and MBR technology integration enable growth within existing footprints.
Plant Upgrade SolutionsMeet stricter discharge limits through targeted process additions. Chemical phosphorus removal, filtration system additions, and UV disinfection upgrades ensure regulatory compliance without complete plant replacement.
Plant Upgrade SolutionsTransform manual operations with PLC/SCADA system upgrades, instrumentation modernisation, and automated chemical dosing. Improve reliability, reduce labour costs, and enable remote monitoring capabilities.
Plant Upgrade Solutions"Will it fit?" and"Will it cope?" are questions our clients never need to ask. Our bespoke sizing methodology ensures every tank, pump, and control system is specified for your exact duty points:
We don't bend your requirements to fit standard tank sizes. Whether you need a 3m³ balance tank or a 150m³ buffer vessel, we fabricate to specification using mild steel (epoxy-coated or rubber-lined), stainless steel (304/316), or GRP construction based on chemical compatibility and site requirements.
Skid-mounted packages for rapid deployment and minimal site works. Containerised DAF plants (C40, C20 configurations) for remote locations or temporary treatment needs. Civil-integrated designs where we supply process mechanicals for concrete structures you construct.
Pumps, blowers, and instrumentation are selected based on your duty cycle–not catalogue defaults. High-viscosity waste from brewery applications receives progressive cavity pumps; abrasive effluents get hard-faced impellers; food-grade applications get EHEDG-certified components.
Comprehensive service contracts, spare parts inventory, and 24/7 technical support ensure your custom equipment continues to perform for its full 20-year design life.
Our bespoke process is collaborative and transparent:
Our bespoke solutions span industries where standard equipment simply cannot deliver:
Handling variable milk waste streams, whey processing, and high-strength BOD (9,000+ mg/L)
Process Integration SolutionsYeast management, grain separation, and high-volume seasonal flow variations
Variable Flow SolutionsMeat, poultry, and ready-meal effluent with high FOG and solids content
Explore Custom EngineeringMetal finishing, chemical processing, and washdown applications
Explore Custom EngineeringContainment, batch variability management, and validation documentation
GMP ComplianceDiscuss your specific requirements with our technical team and receive a tailored proposal for your project.
Contact UsPerformance Ranges & Sizing Criteria
Our bespoke systems are sized against your actual duty points, not catalogue approximations. The following ranges represent typical engineered specifications across our installed base.
| Parameter | Typical Inlet | Guaranteed Outlet | Test Method |
|---|---|---|---|
| BOD₅ | 500 – 9,000 mg/L | < 25 – 100 mg/L | ISO 5815-1 |
| COD | 1,000 – 20,000 mg/L | < 125 – 250 mg/L | ISO 15705 |
| TSS | 200 – 5,000 mg/L | < 30 – 60 mg/L | ISO 11923 |
| FOG | 50 – 2,000 mg/L | < 10 – 15 mg/L | ISO 9377-2 |
| pH | 3.0 – 12.0 | 6.0 – 9.0 | ISO 10523 |
Matching Material to Environment
Material selection is dictated by effluent chemistry, temperature, chloride concentration, and abrasion potential. We do not default to 304 stainless steel unless your effluent justifies it.
AWWA D102-compliant novolac epoxy lining (250–500 µm DFT) for neutral pH effluents and budget-conscious projects. Suitable for BOD/COD streams without chlorides or strong solvents. Service life: 10–15 years with proper maintenance.
304 for food-grade and low-chloride applications (< 50 ppm Cl⁻). 316L with 2.5% molybdenum for moderate chlorides up to 1,000 ppm. Passivated to ASTM A967. Weld decay prevented by controlled heat input and post-weld pickling.
For aggressive chemical effluents, high chlorides (> 5,000 ppm), or seawater ingress. PREN > 35 ensures pitting resistance. Used in offshore, chemical, and metal-finishing applications where 316L would fail within 24 months.
Vinyl-ester or isophthalic GRP for strong acids (pH < 3) and oxidising environments. Dual-laminate PVC/PP-lined GRP for metal pickling and phosphate lines. Temperature limit: 65 °C continuous. No corrosion allowance required.
Hard-natural or chlorobutyl rubber (3–5 mm) for abrasive slurries and high-solids DAF applications. PTFE and Halar coatings for pharmaceutical and aggressive solvent streams. Spark-tested to ASTM D5167.
Chloride > 200 ppm → 316L minimum. pH < 4 or > 10 → consider GRP or rubber. Temperature > 60 °C → avoid standard GRP. Abrasion index > 50 mg/L TSS → hard-faced pumps + rubber-lined vessels.
From Standalone to Fully Integrated
Siemens S7-1200/1500 or Allen-Bradley CompactLogix platforms with local HMI (KTP700 or PanelView). Ideal for single-skid DAF units with 12–32 I/O points. IP65 local panels, stainless steel enclosures for washdown environments.
Full DCS integration via Modbus TCP, PROFINET, or Ethernet/IP. Wonderware, WinCC, or Ignition OPC-UA gateways. Redundant PLCs for critical applications. Historical data logging to plant historians (OSIsoft PI, Canary).
4G/5G or LAN-connected edge gateways with encrypted VPN. Mobile dashboards for flow, pH, dissolved oxygen, and chemical tank levels. SMS and email alerts for alarm conditions. Predictive maintenance via vibration and temperature trending.
Endress+Hauser, Hach, or Krohne instruments specified per duty. pH, ORP, dissolved oxygen, MLSS, turbidity, and flow. Automatic calibration reminders and sensor health diagnostics. ATEX/IECEx sensors for Zone 1/21 hazardous areas.
From Factory Floor to Signed-Off Performance
Witnessed FAT at our ISO 9001 facility includes hydrostatic leak testing (1.5× design pressure), pump curve verification, PLC logic simulation, and HMI screen validation. Full weld inspection reports, material certificates (EN 10204 3.1), and NDT records provided.
Mechanical installation by coded welders (TIG/MIG ASME IX). Pipework flushed and passivated. Electrical termination to BS 7671 or IEC 60364. We coordinate with your M&E contractor or provide turnkey installation crews.
72-hour continuous run proving treatment performance against guaranteed outlet specs. O&M manuals, P&IDs, spare parts lists, and chemical SDS packs handed over. Operator training covers normal operation, alarm response, and seasonal adjustment.
12-month standard warranty extendable to 36 months with a service contract. Performance bonds available for municipal and regulated applications. Penalty clauses for non-achievement of guaranteed outlet quality, subject to agreed inlet conditions.
When your wastewater treatment system needs to fit your process–not the other way around–our bespoke engineering capability delivers. We combine process chemistry expertise with practical mechanical design to create systems that work reliably, comply consistently, and operate technically.
Contact our engineering team today to discuss how a custom-designed solution can resolve your specific wastewater challenges. Whether you're expanding production, facing new discharge limits, or seeking to optimise existing treatment performance, we design the system your application actually requires.
Our expertise spans multiple industries with sector-specific water treatment solutions.