Double-pass casting was evaluated as a technique to overcome hard-to-cast membranes or hard-to-mix solutions. Two types of polyethersulfone (PES) membranes were tested, one incorporating a hydrophilic surface modifying additive and the other with a hydrophobic one. It was found that the morphological improvement was more obvious for hydrophobic membranes since their solutions were not completely homogenous and hard-to-cast. The double-pass hydrophobic membranes had smoother surfaces and more porous support layers, resulting in higher fluxes, higher volume of treated water (67.4% increase) but decreased natural organic matters (NOM) rejection. The new casting approach produced hydrophilic membranes having a spongy structure (as opposed to finger-like cavities), yet they had similar NOM rejection, a 12.4% higher flux than the single-pass membranes prepared from the same dope. This is attributed to the quite homogenous hydrophilic casting solutions and to the performance of the original hydrophilic membranes (single-pass casting) that was relatively good. (C) 2008 Elsevier B.V. All rights reserved.