Sustainable Co-Production of Xylanase, Cellulase, and Pectinase through Agroindustrial Residue Valorization Using Solid-State Fermentation: A Techno-Economic Assessment

Abstract

This work describes the evaluation of the solid-state fermentation (SSF) bioprocess utilizing brewery spent grain (BSG) and apple pomace (AP) as carbon sources and matrices for microorganism growth to produce xylanase, pectinase, and cellulase. The process was assessed at a larger scale by designing a packed column-type bioreactor equipped with sensors for monitoring critical parameters such as CO2 concentration, humidity, and temperature. Then, process simulation was used to evaluate the techno-economic feasibility of the bioprocess at an industrial scale. The analysis centered on evaluating which formulation, primarily containing xylanase (scenario 1), pectinase (scenario 2), or cellulase (scenario 3), yielded the most promising results for advancing to the commercial stage. Additionally, a sensitivity analysis was conducted to explore the influence of variations in raw material costs and enzyme prices. The obtained results at a higher scale were within the expected results obtained under optimum conditions. Scenario 1 exhibited strong economic viability with further optimization potential (base case: 5000 kg/batch with an ROI of 37.59%, payback time of 2.66 years, IRR of 26.8%, and net present value of USD 7,325,537). The sensitivity analysis revealed that changes in enzyme prices, particularly xylanase, could significantly influence the process’s profitability. This study also demonstrated the potential for cost optimization by selecting a more cost-effective inoculum media and optimizing water usage to enhance process efficiency and sustainability.