MBR Retrofit & Life Extension

Upgrade the Plant You Already Have

M|MBR helps owners, engineers, contractors, and operators choose the right retrofit path, specify the right equipment, and keep the plant in service while the work gets done.

LIFE
EXTENSION
Existing Infrastructure

INCREASE
CAPACITY

uP TO 2-3x

improve performance

reduce operating costs

UPGRADE
PROCESS

NUTRIENT REMOVAL
AND RECLAIM CAPABILITIES

What We Offer, and Why We're Different

Which retrofit do you need?

Conventional Plant

Converting a conventional plant to MBR

CAS, SBR, RBC, and lagoon systems converted to membrane treatment, usually inside the tanks you already own. Driven by capacity limits, tightening permits, footprint constraints, or a reuse requirement.

MBR Plant

Upgrading an existing MBR plant

New membranes, controls, and process equipment for an MBR that is aging, maintenance-heavy, locked to an obsolete product, or out of capacity within its current footprint.

What We Offer

M|MBR supports customers evaluating MBR retrofit projects with product-related design, installation, startup, and ongoing support services. We provide the equipment and components needed for an upgrade as loose parts, integrated assemblies, or part of a turnkey delivery.

We are not an engineering firm. We are MBR technology experts. We complement and augment project engineering capabilities.

Why We're Different

We specialize in retrofitting conventional wastewater treatment systems and modernizing existing MBR plants, bringing long-term experience, global technology partnerships, local manufacturing relationships, and dedicated controls and integration capabilities to each project. From our MBR Tech Hub in Texas, we maintain membrane technology inventory to support faster delivery when schedules matter.

Who We Work With

M|MBR can support any project type. We specialize in supporting private utilities, tribal communities, developers, middle-market municipalities, decentralized, and reuse applications.

We’re proud of the 400+ projects we’ve helped deliver, but prouder of the long-term relationships behind them. Repeat business across multiple projects is the strongest proof that customers trust us to get retrofit work done right.

11 MGD PLANT
Saved
$ 0 M

The total project cost to retrofit existing tanks to MBR versus building a new SBR.

0.3 MGD PLANT
Added Capacity
0 %

Aftermarket upgrade of older membrane equipment.

0.2 MGD PLANT
Less Expensive
0 %

$400K MBR upgrade versus $800K competing offer.

0.4 MGD PLANT
Estimated Monthly Savings
$ 0 K

Eliminated daily hauling during peak season at an RV park.

Definition Of Retrofit

What We Mean by “Retrofit”

A retrofit is a modification or upgrade to an existing, operating wastewater treatment plant. Our work falls into two categories : converting a conventional plant such as CAS or SBR to MBR, or upgrading an existing MBR with new membranes, controls, and process equipment. In both cases the goal is the same: better treatment, more capacity, and longer asset life without building a new facility. Five types cover most of what we do.

01

Membrane Conversion

Replacing one membrane technology or brand with another within an existing MBR, or converting a conventional plant to membrane-based treatment.

02

Process Upgrade

Reconfiguring or adding biological treatment zones to change what the plant removes. For example, adding anoxic zones for nitrogen or converting CAS to MBR.

03

Compliance Upgrade

Modifications driven by a new or tightened permit requirement: reuse classification, nutrient limits, or a discharge class change.

04

Controls Upgrade

SCADA, PLC, instrumentation, or automation improvements without changing the biological or membrane process.

05

Capacity Expansion

Adding tankage, membrane trains, or equipment to increase throughput at an existing site.

Scope Comparison by Retrofit Category

Membrane Swap

Process Upgrade

Capacity Expansion

Compliance Retrofit

Controls Retrofit

Brownfield Retrofit

Path One

Converting Conventional Plants to MBR

These projects show how M|MBR has helped stakeholders convert conventional treatment systems, such as CAS, SBR, and RBC, into MBR plants. They are often driven by capacity limits, treatment upgrades, footprint constraints, or regulatory changes.

Small Plant

0.10 MGD → 0.20 MGD

Rio Del Oro, NM

CAS to MBR • Converted 2006

M|MBR supported the conversion of an existing CAS plant to an MBR in 2006. In 2025, M|MBR was brought back to expand plant capacity during a live upgrade by converting to a more efficient membrane technology.

“Going MBR was 50% less expensive than using conventional technology to upgrade and expand the old plant.”

Why M|MBR: Trust, proven experience, multi-disciplinary team, technology, vertical integration.

Medium Plant

0.60 MGD → 1.04 MGD

Running Springs, CA

CAS to MBR • Converted 2002

M|MBR supported the conversion of an existing CAS plant to a 0.60-MGD MBR in 2002, then returned on several occasions for technology upgrades as part of plant expansions. In 2025, M|MBR replaced antiquated flat sheet product with a newer product.

“I have been working with some of the guys at M|MBR Systems for years, since 2002. They’re all extremely knowledgeable about MBR and passionate about what they do.”

Why M|MBR: Experience, multi-disciplinary team, technology, vertical integration. Guaranteed not-to-exceed price.

Large Plant

6.0 MGD → 10.8 MGD

Clairton, PA

CAS to MBR • 15-Yr Design & Construction

Concrete tanks built in the 1970s were converted into 4 MBR trains, raising capacity from 6 MGD to 10.83 MGD average and 9.7 MGD to 38 MGD peak. A live, brownfield upgrade spanning almost 3 years.

“Over the last 15 years, we have built a repertoire with Dennis and his team. They’re great guys. We’ve done several projects.”

Why M|MBR: Trust, proven experience, multi-disciplinary team, technology, vertical integration.

Path Two

Upgrading an Existing MBR Plant

We’ve upgraded and expanded numerous existing MBR facilities with new membrane equipment, controls, and process upgrades. These projects are typically driven by aging assets, maintenance burden, performance goals, or the need to add capacity within the current plant footprint.

Small Plant

0.025 MGD

Pilot Travel Center, MA

Packaged MBR • RBC Retrofit • 2013 / 2025

M|MBR delivered a packaged 0.025-MGD MBR system in 2013 as part of an RBC retrofit. In 2025, M|MBR returned to remediate the plant with new fine screens, membrane units, anoxic and aeration basin equipment, feed-forward pumps, a new control panel and HMI, plus startup and training. The new membrane units added 75% more filtration area, decreasing maintenance and increasing uptime.

Why M|MBR: Experience, multi-disciplinary team, technology, vertical integration. Pre-selected by the project engineer. Performance bond included.

Life Extension

Medium Plant

0.30 MGD → 0.42 MGD

Rio Del Oro, NM

CAS to MBR 2002 • Upgraded 2025

M|MBR supported the conversion of an existing CAS plant to an MBR in 2002. In 2025, M|MBR replaced antiquated flat sheet product with a newer product in a turnkey project: new permeate piping, new VFDs, new permeate pumps, new membrane equipment, and programming modifications. Completed live, while the plant received design flowrates.

Why M|MBR: Experience, multi-disciplinary team, technology, vertical integration. Guaranteed not-to-exceed price.

Expansion

Large Plant

1.50 MGD → 1.90 MGD

Ballina, Australia

Live MBR Retrofit • 4 Phases / 6 Months

M|MBR supported the conversion of an existing MBR. This live retrofit was completed in 4 phases over about a 6-month period. The overall upgrade included new UV technology, new membrane equipment, and other plant modifications.

Why M|MBR: Experience, multi-disciplinary team, technology, vertical integration.

Expansion
Life Extension Services

Single Source Responsability,
Lifecycle Accountability

The design, project management, installation, commissioning, startup, and support services needed to deliver retrofit projects are collectively referred to as asset Life Extension Services. One team, one scope, from the first site walk to the plant back in full operation.

Design

Retrofit-specific product design, equipment selection, and integration with the project engineer’s drawings.

Project Management

One point of contact, one schedule, one accountable party across the equipment scope.

Installation

Loose parts, integrated assemblies, or full turnkey installation, depending on how you want to run the job.

Commissioning

Functional testing and process tuning against the permit you have to meet.

Startup

Bringing membranes and controls online, with operator training on the equipment as installed.

Ongoing Support

Technical support, spares, and service after the contractor demobilizes.

Frequently Asked Questions

Common questions about MBR retrofits

Usually, yes. Most of our retrofits are phased so the plant keeps treating flow throughout. One recent upgrade ran four phases across about six months while the plant stayed online; a large conversion held service across roughly three years of construction. Phasing is planned around your flows, not around our schedule.

Often. Converting existing concrete to MBR trains is one of the most common ways a retrofit beats new construction on cost. A 1970s CAS basin set was converted into four MBR trains and now carries 10.8 MGD average flow.

It depends on tankage, hydraulics, and permit limits. Across the projects on this site the range runs from about 27% to 81% additional capacity within the existing footprint.

No. We are membrane-agnostic and work across multiple technologies and brands, including part-for-part backward-compatible replacements. Being locked to a discontinued product is one of the most common reasons owners call us.

From packaged systems around 0.025 MGD up to multi-MGD municipal facilities.
Both are available, but the distinction matters. We are not a design engineering firm. We provide product-related design and the equipment scope, and we work alongside your engineer of record. Where you want fewer seams, we can carry the scope through installation, commissioning, and startup.
Start with what the existing asset can still do. If the tanks are sound and the site is constrained, a conversion is often materially cheaper — one owner put the MBR route at 50% less than a conventional upgrade and expansion, and another saved $6M against new construction. Where the tankage is at end of life, a packaged or modular plant may win. We will tell you which one we think it is.