Enhancing Food Safety, Quality and Sustainability Through Biopesticide Production Under the Concept of Process Intensification

The worldwide population is anticipated to reach 10.12 billion by the year 2100, thereby amplifying the necessity for sustainable agricultural methodologies to secure food availability while reducing ecological consequences. Conventional synthetic pesticides, while capable of increasing crop yields by as much as 50%, present considerable hazards such as toxicity, the emergence of resistance, and environmental pollution. This review examines biopesticides, originating from microbial (e.g., Bacillus thuringiensis, Trichoderma spp.), plant, or animal sources, as environmentally sustainable alternatives which address pest control through mechanisms including antibiosis, hyperparasitism, and competition. Biopesticides provide advantages such as biodegradability, minimal toxicity to non-target organisms, and a lower likelihood of resistance development. The global market for biopesticides is projected to be valued between USD 8 and 10 billion by 2025, accounting for 3–4% of the overall pesticide sector, and is expected to grow at a compound annual growth rate (CAGR) of 12–16%. To mitigate production costs, agro-industrial byproducts such as rice husk and starch wastewater can be utilized as economical substrates in both solid-state and submerged fermentation processes, which may lead to a reduction in expenses ranging from 35% to 59%. Strategies for process intensification, such as the implementation of intensified bioreactors, continuous cultivation methods, and artificial intelligence (AI)-driven monitoring systems, significantly improve the upstream stages (including strain development and fermentation), downstream processes (such as purification and drying), and formulation phases. These advancements result in enhanced productivity, reduced energy consumption, and greater product stability. Patent activity, exemplified by 2371 documents from 1982 to 2021, highlights advancements in formulations and microbial strains. The integration of circular economy principles in biopesticide production through process intensification enhances the safety, quality, and sustainability of food systems. Projections suggest that by the 2040s to 2050s, biopesticides may achieve market parity with synthetic alternatives. Obstacles encompass the alignment of regulations and the ability to scale in order to completely achieve these benefits.