<![CDATA[Downstream separation is a critical determinant of efficiency, cost, and sustainability in industrial bioprocessing. This study investigates the potential of integrated downstream separation strategies to enhance bioprocess performance compared to conventional multistep systems. The objective is to evaluate improvements in product recovery, purity, energy and water efficiency, environmental impact, and economic viability. A comparative assessment was conducted across four separation strategies: conventional multistep, integrated extraction with distillation, membrane with polishing, and adsorption with desorption. Key performance metrics recovery yield, product purity, energy demand, and water use were quantified alongside environmental indicators (CO₂ emissions, solvent loss, wastewater COD) and economic indicators (CAPEX, OPEX, NPV, IRR). Results showed that integrated systems outperformed conventional ones in every evaluated category. Membrane systems achieved the highest product purity (98%) and lowest energy demand (25.5 MJ/kg), while adsorption-based systems delivered the highest recovery yield (85%). Integrated strategies reduced CO₂ emissions by 37.9%, solvent loss by 61.1%, and wastewater COD by 46.9%. Economically, integrated systems showed strong viability with a payback period of 2.0 years, an IRR of 26.7%, and a net present value of USD +820,000. These findings suggest that integrated downstream systems offer substantial gains in efficiency, environmental sustainability, and financial performance. Their implementation supports circular economy principles and provides a strategic pathway for sustainable industrial bioprocessing. Continued validation and scale-up studies are recommended to advance adoption across the biomanufacturing sector.]]>
Copyrights © 2025
