Optimization of Downstream Processing for Industrial Bioproducts: Recovery, Purification, and Formulation

Downstream processing (DSP) covers everything that happens after the target product has already been formed by fermentation or biocatalysis: the recovery, separation, purification, and formulation of that product from a complex broth. It applies across the full range of industrial bioproducts, including proteins and enzymes, organic acids, amino acids, biofuels, biopolymers, fine and specialty biochemicals, and biopharmaceuticals. DSP is often the largest contributor to production cost and a decisive factor in product quality, yet it has historically received less attention than strain development and fermentation. Common unit operations include cell harvesting, cell disruption, clarification, extraction, chromatography, membrane filtration, precipitation, crystallization, and drying.Despite steady progress, DSP remains a major bottleneck in industrial biomanufacturing. Dilute product titers, complex feedstocks, similar physicochemical properties between product and impurities, product instability, and the presence of host cell proteins, nucleic acids, and other contaminants all complicate recovery. Achieving high yield and purity while controlling cost, water and solvent use, and environmental footprint is a persistent challenge, and performance often degrades during scale-up. Emerging approaches such as continuous and integrated processing, novel adsorbents and membranes, aqueous two-phase and other green separation systems, process analytical technology (PAT), and model-based and data-driven optimization are reshaping the field, but a gap remains between laboratory demonstrations and robust, scalable, and sustainable industrial processes.GoalThis Research Topic aims to gather cutting-edge and novel research that advances downstream processing for industrial bioproducts, from initial product recovery to final formulation. The collection will showcase approaches that improve recovery yield, purity, productivity, and robustness, while reducing cost and environmental impact and strengthening reproducibility at scale. We particularly encourage contributions that apply artificial intelligence and machine learning to optimize downstream operations, leverage digital bioprocessing tools, and embed circular bioeconomy principles for resource-efficient biomanufacturing. The focus is on the recovery, separation, purification, and formulation train that begins once the product has been produced, rather than on strain engineering, fermentation optimization, or feedstock pretreatment and conversion, which fall outside the scope of this collection except where they directly address downstream recovery. By bringing together perspectives from across product classes and unit operations, we hope to foster dialogue among microbiologists, biochemists, bioprocess engineers, and data scientists around shared challenges in bioseparations and to support more efficient and sustainable biomanufacturing.ScopeWe welcome contributions that address the recovery, purification, and formulation stages of bioprocessing, with an emphasis on cutting-edge and novel downstream processes. The following is a non-exhaustive list of subjects to be covered in this Research Topic:o AI and machine learning-driven optimization of downstream operationso Digital bioprocessing tools, digital twins, and smart manufacturing approaches for DSPo Cell harvesting, clarification, and solid-liquid separation strategies for microbial brothso Cell disruption and primary recovery of intracellular productso Chromatographic purification: novel resins, ligands, membrane and continuous chromatographyo Membrane-based separations: micro-, ultra-, nano-, and diafiltration, and hybrid systemso Extraction-based recovery, including aqueous two-phase systems, and other green separation approacheso Precipitation, crystallization, and drying for product isolation and stabilizationo Formulation, stabilization, and shelf-life of microbial and enzymatic productso Continuous, integrated, and intensified downstream processingo Process analytical technology (PAT), sensors, and real-time monitoring in DSPo Modeling, simulation, scale-up, and data-driven optimization of downstream operationso Circular bioeconomy approaches for resource-efficient biomanufacturing, focused on recovery and reuse of value from process streamso Sustainable DSP: reducing water, solvent, and energy use, and minimizing wasteo Techno-economic analysis and case studies linking DSP design to product quality and manufacturing outcomes Topic editors: Everaldo Santos, Pranav Deepak Pathak, Sundaramahalingam M A Source: https://www.frontiersin.org/research-topics/83074/optimization-of-downstream-processing-for-industrial-bioproducts-recovery-purification-and-formulation