This is an illustrative scenario showing how Reynolds & Bauhm equipment can be configured for this application. Every site has unique requirements — contact us for a solution tailored to your specific wastewater characteristics.
Ready-meal manufacturing facility generates 280 m3/day of CIP wastewater containing caustic soda (pH 12-13), phosphoric acid rinse (pH 1-2), food residues, and detergents. Current practice is direct sewer discharge with high chemical requirements. Target: 70% water recovery for reuse in non-critical washing applications.
Step-by-step process configuration from raw wastewater to compliant discharge.
Acidic and alkaline CIP streams collected in separate 20 m3 batch tanks. Conductivity monitoring identifies chemical strength for potential direct reuse in weaker CIP cycles. Caustic streams with >1% NaOH diverted for direct reuse.
Two-stage automated pH correction: caustic streams dosed with recovered phosphoric acid rinse; acid streams dosed with lime slurry. pH controlled to 7.0 +/- 0.5. Chemical consumption reduced by 40% through internal acid-alkali balancing.
Lamella clarifier removes food residues and soap precipitates at 8 m/h upflow velocity. Effluent TSS <20 mg/L. Settled sludge at 4% solids pumped to screw thickener. Chemical coagulant dose optimised at 15 mg/L ferric chloride.
Dual-media sand/anthracite filter captures residual suspended solids and organics. Automatic backwash on headloss trigger. Effluent turbidity <2 NTU, suitable for cooling tower makeup and floor washing.
Medium-pressure UV provides disinfection to <100 CFU/100mL for non-potable reuse. Treated water stored in 100 m3 reuse tank for distribution to floor wash stations, cooling tower makeup, and vehicle wash. 70% recovery achieved consistently.
The specific equipment selected for this application, sized for the flow rate and contaminant load.
Two-stage automated pH control, acid/alkali recovery, 30 m3 reaction tanks, PLC control.
View EquipmentSS construction, 40 m2 settling area, integrated sludge hopper, 8 m/h design.
View EquipmentDual-media sand/anthracite, 1.5 m diameter, automatic backwash, turbidity monitor.
View EquipmentRepresentative performance data based on typical operating conditions for this equipment configuration.
Explore the full range of equipment used in this and similar applications.
Discover how these treatment processes connect to form complete wastewater treatment solutions.
Reynolds & Bauhm follows a structured engineering methodology for every project. We begin with detailed wastewater characterisation, process selection based on contaminant profiles, pilot testing where required, and full-scale design with performance guarantees. Our multidisciplinary team of chemical, mechanical, and electrical engineers ensures seamless integration of process, mechanical, and control disciplines.
Comprehensive influent analysis including COD, BOD, TSS, heavy metals, pH, temperature, and flow profiling.
Process flow development with P&IDs, mass balances, and hydraulic modelling validated by CFD where appropriate.
On-site pilot trials validate performance guarantees under actual operating conditions before capital commitment.
FAT, SAT, performance trials, operator training, and handover documentation ensuring operational readiness.
| Pre-Treatment | Screening, grit removal, and flow equalisation |
| Primary Treatment | DAF or lamella clarification for solids and oil removal |
| Secondary Treatment | Biological oxidation (activated sludge, MBBR, or SBR) |
| Tertiary Treatment | Filtration, UV disinfection, or chemical polishing |
| Sludge Management | Thickening and dewatering via belt press or centrifuge |
| Control System | PLC with HMI touchscreen and optional SCADA integration |
| Chemical Dosing | Automated coagulant, flocculant, and pH correction |
| Materials | SS316L, duplex, or rubber-lined carbon steel |
85 – 98% chemical oxygen demand reduction depending on process configuration and influent variability.
90 – 99% suspended solids reduction through combined physical and biological treatment stages.
Tertiary treatment enables up to 80% water recycling for non-potable process applications.
Our engineers will adapt this equipment configuration to your specific wastewater analysis, flow rate, and discharge requirements.
Our expertise spans multiple industries with sector-specific water treatment solutions.