De novo gamma-decalactone bioproduction from Ashbya gossypii: Process design, techno-economic evaluation and environmental assessment.

γ-decalactone (GDL) is a high-value lactone renowned for its natural peach aroma, with broad applications in the food, fragrance, and cosmetics sectors. This study presents integrated evaluation of GDL production via de novo fermentation using Ashbya gossypii, combining technical, economic, and environmental analyses to assess its industrial feasibility. Process simulations predict substantial annual GDL yields with a final purity close to 96%, achieved through downstream processing comprising adsorption resins and ethanol recovery after extraction. The techno-economic assessment showed that economic performance is strongly affected by the cost of myo-inositol and the low fermentation titer. However, competitiveness may be possible under favourable market and process improvement scenarios. Life cycle analysis (LCA) identifies key contributors to environmental impact such as mineral salts, steam, and resin, while sensitivity analysis reveals optimization opportunities that could substantially reduce these burdens. Although residual biomass valorization could provide an additional revenue stream, its contribution remains secondary compared to GDL sales. This work demonstrates a promising and scalable biosynthetic route for producing high-purity, natural GDL, offering a strategic alternative to conventional extraction methods.