<![CDATA[Conventional fermentation processes face critical challenges, including low productivity, high downstream costs, and substantial environmental impact due to product inhibition and waste generation. This study aims to evaluate the integration of in situ product recovery (ISPR) into fermentation systems, assessing its economic and environmental benefits through a lifecycle perspective. A comparative analysis was conducted using performance data from conventional and ISPR-integrated bioprocesses. Key metrics included product titer, volumetric productivity, energy use, waste generation, and downstream cost fractions. Various ISPR configurations such as membrane and resin-based systems were evaluated using life cycle assessment and cost analysis frameworks. Integration of ISPR improved product titer by up to 50%, volumetric productivity by over 59%, and reduced fermentation time by up to 6 hours. Waste output and energy consumption were significantly lowered, especially in membrane-based systems. Downstream processing costs traditionally comprising 30–50% of total operational expenditure were reduced by up to 40%. Environmental benefits included lower carbon emissions and improved substrate utilization efficiency. However, the success of ISPR at scale depends on factors such as solvent regeneration cost, system compatibility, and long-term sustainability of extraction methods. ISPR integration enhances the efficiency, economic viability, and sustainability of fermentation processes. It offers a promising pathway toward scalable and environmentally responsible biomanufacturing. Further innovation in ISPR technologies and digital process control is recommended to maximize long-term impact.]]>
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