INDUSTRIAL WASTE WATER TREATMENT

Bespoke Packaged Plant

At Barr + Wray we specialise in the complete delivery of industrial wastewater treatment plants, offering end-to-end services from detailed design through to installation, commissioning, and ongoing maintenance.

Our holistic approach ensures our clients receive tailored, high-performance treatment systems that meet their unique process requirements and regulatory standards.

Our engineering team takes full ownership of the installation process, with all systems installed by Barr + Wray’s own skilled engineers. This guarantees consistent quality, safety, and adherence to project timelines. We utilise only high-quality equipment sourced from our network of trusted global suppliers, ensuring reliability and longevity of each component.

Every plant supplied by Barr + Wray is fully equipped with critical infrastructure, including custom-designed control panels, HMI’s, automated valves, pipework, instrumentation, tanks, and other essential mechanical and electrical elements. Our integrated control systems provide real-time monitoring and precise process control, optimising treatment performance and operational efficiency.

Throughout the commissioning phase, Barr + Wray engineers work closely with clients to ensure smooth start-up, system validation, and staff training – ensuring operational confidence from day one.

Beyond project delivery, Barr + Wray offers comprehensive service and maintenance packages, supporting long-term plant performance and reliability. Our proactive maintenance programs, including scheduled inspections, preventative servicing, and rapid response troubleshooting, help minimise downtime and extend asset life.

Systems can be supplied fully skid-mounted, housed within a containerised packaged plant, or installed directly within the client’s existing plantroom. This flexible approach allows Barr + Wray to meet a wide range of space, accessibility, and operational requirements across different industrial environments.

pH Correction

With over 60 years of engineering experience, Barr + Wray has built a strong reputation in delivering effective water treatment solutions, including the essential process of pH correction in industrial wastewater treatment. Our systems are designed to manage complex effluent streams across a range of industries, such as manufacturing, pharmaceuticals, petrochemicals, electronics,  and food processing.

At Barr + Wray we provide customised pH correction solutions, utilising advanced chemical dosing equipment, real-time monitoring, and automated control systems. These solutions ensure accurate pH adjustment, helping our clients meet environmental discharge regulations while protecting downstream infrastructure and ecosystems.

Key components include proportional dosing pumps, calibrated pH sensors, and PLC-based automation, enabling systems to respond dynamically to changing influent conditions. This approach reduces chemical consumption, lowers operational costs, and maintains consistent performance. Their modular designs can be integrated into existing treatment plants or developed as part of new facilities.

Barr + Wray also delivers comprehensive lifecycle support—from initial consultation and system design to installation, commissioning, and ongoing service. Our engineering team has significant experience in handling variable and corrosive effluents, ensuring durability and efficiency of the system over time.

Through a focus on compliance, sustainability, and operational efficiency, Barr + Wray supports industrial clients in achieving reliable pH correction, contributing to responsible wastewater management and reduced environmental impact.

Solids Removal

Solids removal is a fundamental stage in industrial wastewater treatment, targeting the elimination of suspended and settleable solids that may disrupt downstream processes or result in non-compliant effluent discharge. These solids typically include organic material, grit, silt, metal particles, fibres, and process-generated sludge.

At Barr + Wray, we engineer solids removal systems as an integral component of our turnkey treatment solutions. Our process design begins with mechanical screening or bar racks, removing coarse debris that could obstruct or damage subsequent treatment stages.

This is followed by grit removal systems, designed to extract dense, abrasive particles that would otherwise accelerate wear on pumps, valves, and pipelines.

Primary sedimentation (clarification) is employed to settle heavier solids under gravity, while floating materials are removed via surface skimming. Where fine, non-settleable particles are present, coagulation and flocculation systems are integrated to promote agglomeration into larger, settleable flocs.

For enhanced removal efficiency, Barr + Wray can incorporate Dissolved Air Flotation (DAF) units, particularly suited for the separation of light solids, oils, and greases.

In applications requiring high clarity, we offer filtration solutions—including sand filters, disc filters, and membrane technologies—to capture residual suspended solids.

All systems are designed to minimise chemical and energy consumption while maximising solids capture efficiency and operational reliability.

Whether delivered as a containerised packaged plant or installed in the client’s plantroom, Barr + Wray’s solids removal systems are tailored to the specific characteristics of the wastewater stream and the performance requirements of the overall treatment process.

Our solutions ensure effective solids separation, protect downstream treatment assets, and help clients meet stringent environmental discharge standards.

Sedimentation

Sedimentation is a fundamental physical process within Barr + Wray’s industrial wastewater treatment systems, designed to remove suspended solids by allowing them to settle under gravity. Typically positioned after preliminary treatment (e.g. screening or grit removal), sedimentation plays a critical role in reducing solids load prior to chemical or biological treatment stages.

In this process, wastewater is directed into a clarifier or settling tank, where flow velocity is significantly reduced. This allows heavier particles—such as grit, sand, metal fines, and process solids—to settle at the base, forming sludge. The clarified water (supernatant) is then discharged from the top for further treatment.

Barr + Wray designs and supplies various types of sedimentation systems, tailored to application-specific requirements:

• Primary Clarifiers – for the removal of bulk solids prior to downstream biological treatment
• Secondary Clarifiers – used to separate biological sludge following activated sludge or similar processes
• Lamella Separators – compact, inclined-plate systems ideal for applications with limited footprint or higher flow rates

To enhance sedimentation efficiency, Barr + Wray integrates chemical dosing systems where required—delivering coagulants and flocculants upstream to bind fine particles into settleable flocs. Factors such as particle size, density, hydraulic loading rate, temperature, and retention time are carefully accounted for in system design.

All sedimentation units are engineered for reliability, ease of sludge removal, and minimal maintenance. Whether integrated into a containerised packaged plant or a site-based installation, our sedimentation solutions are custom-built to handle varying industrial loads and effluent characteristics.

By incorporating efficient sedimentation into the overall treatment process, Barr + Wray ensures optimal solids reduction, improved downstream process performance, and full regulatory compliance for industrial wastewater discharge.

Coagulation

Coagulation is a core process integrated into Barr + Wray’s industrial wastewater treatment systems, designed to destabilise and aggregate fine suspended solids, colloids, and certain dissolved substances that are otherwise difficult to settle or filter. These particles typically carry surface electrical charges, which keep them dispersed and contribute to turbidity in wastewater.

The coagulation process involves the controlled addition of inorganic coagulants such as aluminium sulphate (alum), ferric chloride, or polyaluminium chloride (PAC). These chemicals neutralise surface charges, allowing fine particles to bind together into larger, denser clusters known as microflocs.

Once formed, these flocs can be effectively removed via flocculation, sedimentation, dissolved air flotation (DAF), or filtration. Coagulation significantly enhances the removal of:

• Fine suspended solids and silt
• Dissolved organic matter
• Phosphates and nutrient loads
• Colour-causing compounds and dyes

Barr + Wray incorporates coagulation as part of our tailored treatment systems, especially where high contaminant loads or low turbidity removal targets are required. Coagulation is applied both as a standalone stage, and in conjunction with advanced physical and chemical processes to optimise treatment efficiency and discharge compliance.

Critical to coagulation performance is the precise control of chemical dosing, pH, mixing energy, and reaction time.

Barr + Wray designs systems with fully automated dosing and monitoring equipment, ensuring optimal reagent use, operational reliability, and consistent performance under variable load conditions.

Whether integrated into a containerised packaged plant or a fixed-site installation, Barr + Wray’s coagulation systems play a key role in improving downstream process efficiency and achieving robust, regulatory-compliant wastewater treatment for a wide range of industrial applications.

Disinfection

As part of our comprehensive wastewater treatment solutions, Barr + Wray integrates advanced disinfection systems to ensure treated effluent meets stringent microbial and environmental discharge standards.

Disinfection is the final barrier in the treatment process, targeting the removal or inactivation of harmful pathogens, bacteria, viruses, and parasites.

Depending on the application, effluent quality targets, and site-specific requirements, Barr + Wray selects and integrates the most suitable disinfection technology, such as:

• UV Disinfection: We design systems using ultraviolet (UV) light which inactivates microorganisms by damaging their DNA. UV treatment is chemical-free, highly effective, and particularly well-suited to applications where residual chemicals are undesirable -such as water reuse or environmentally sensitive discharges.
• Ozone Disinfection: For high-purity applications or where additional oxidation is beneficial, ozone systems are installed. Ozone is a powerful oxidant capable of destroying a wide range of pathogens while also reducing odour, colour, and certain organic contaminants. Barr + Wray provides fully automated ozone generation and dosing systems, safely integrated into the plant’s control systems.
• Chemical Disinfection: Chlorine-based systems (e.g., sodium hypochlorite or chlorine dioxide) are commonly used for effective, residual disinfection. These are especially suitable for larger-scale or long retention systems. Our chemical dosing systems are equipped with safety interlocks, real-time monitoring, and automated controls to ensure optimal dosing and operator safety.

Barr + Wray’s disinfection solutions are delivered as part of containerised packaged plants or custom plantroom installations, with full integration into PLC/SCADA systems for monitoring and performance assurance.