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<p>Bacterial cellulose (BC) has emerged as a benchmark biopolymer for diverse industrial applications, particularly in biomedical, functional food, packaging, and cosmetic sectors. Its exceptional properties, including superior mechanical strength, thermal stability, chemical tunability, biocompatibility, biodegradability, and a highly porous nanofibrillar architecture, have further enabled its utilization in agriculture, environmental remediation, electronics, textiles, and paper industries. Despite its immense potential, widespread industrial adoption of BC faces a critical economic barrier: prohibitively high production costs. Key challenges include expensive culture media, low-efficiency microbial strains, suboptimal productivity rates, incomplete substrate utilization, and metabolic byproduct accumulation. Although contemporary strategies such as media optimization, genetic engineering, fermentation technology, and bioreactor design have improved yields, productivity, and profitability, achieving cost-competitive large-scale BC production remains an open challenge. A sustainable bioeconomic framework is presented here by developing a Block Flow Diagram (BFD) to valorize agro-industrial residues as low-cost substrates. Through the BFD analysis in a cohort with a comprehensive literature review of BC production optimization, standardized characterization, and innovative applications, this study evaluates progress toward techno-economic sustainability and identifies key areas for future improvements. The key insights from this research provide a roadmap for sustainable BC commercialization, emphasizing waste-derived feedstocks and process efficiency enhancements.</p>

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Bacterial cellulose production, scale-up, and applications: a techno-economic study of industry-ready bacterial cellulose production from industrial and agro wastes

  • 期刊论文

  • 发表日期：

    2025年12月9日

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  • Poulami Mukherjee,
  • Rajashree D. Kamble,
  • J. B. Venkata Krishnan,
  • Senthilkumar Sivaprakasam,
  • Sreedeep Sekharan

摘要

Bacterial cellulose (BC) has emerged as a benchmark biopolymer for diverse industrial applications, particularly in biomedical, functional food, packaging, and cosmetic sectors. Its exceptional properties, including superior mechanical strength, thermal stability, chemical tunability, biocompatibility, biodegradability, and a highly porous nanofibrillar architecture, have further enabled its utilization in agriculture, environmental remediation, electronics, textiles, and paper industries. Despite its immense potential, widespread industrial adoption of BC faces a critical economic barrier: prohibitively high production costs. Key challenges include expensive culture media, low-efficiency microbial strains, suboptimal productivity rates, incomplete substrate utilization, and metabolic byproduct accumulation. Although contemporary strategies such as media optimization, genetic engineering, fermentation technology, and bioreactor design have improved yields, productivity, and profitability, achieving cost-competitive large-scale BC production remains an open challenge. A sustainable bioeconomic framework is presented here by developing a Block Flow Diagram (BFD) to valorize agro-industrial residues as low-cost substrates. Through the BFD analysis in a cohort with a comprehensive literature review of BC production optimization, standardized characterization, and innovative applications, this study evaluates progress toward techno-economic sustainability and identifies key areas for future improvements. The key insights from this research provide a roadmap for sustainable BC commercialization, emphasizing waste-derived feedstocks and process efficiency enhancements.