Early-stage economic and environmental impact assessment for optimized bioprocess development: Monoterpenoid indole alkaloids

Microbial refactoring offers sustainable production of plant-sourced pharmaceuticals associated with high production costs, ecological harms, and supply chain dependencies. Here, microbial tabersonine production in Saccharomyces cerevisiae is modeled during early-stage development (TRL: 3–5), guiding decisions for process-scale economic and environmental optimization. The base-case 0.7 mg/L titer indicated a minimum selling price (MSP) of $3,910,000/kg and global warming potential (GWP) of 2,540 kgCO₂eq/g. The industrial process at 1 g/L resulted in an MSP of 4,262 $/kg and a GWP of 6.36 kgCO₂eq/g. Location analysis indicated a sustainability trade-off between France, USA, Poland, and China, with the written order of declining MSP and increasing GWP. Continuous processing promised reducing the MSP by 18–27 %, and the GWP by 17–31 %. In-situ product extraction during fermentation was estimated to lower the MSP by 41–61 %, and the GWP by 30–75 %. In addition to showcasing a combined TEA-LCA on biopharmaceuticals, the early-stage assessment approach guides bioprocess optimization.