10179707BioForge: Circular Biomanufacturing for a resource-efficient futureClosedCollaborative R&DInnovate UKBioForge is a **groundbreaking innovation** designed to help the UK tackle its two greatest industrial challenges: relying too heavily on **imported raw chemicals** and failing to effectively use the massive volumes of **waste** generated by British farms and factories. Instead of seeing millions of tonnes of **organic by-products** produced each year as a disposal problem, we see it as a vast **renewable resource**. This initiative will also demonstrate how integrating **advanced AI** with **biotechnology** can transform waste into **valuable feedstocks** while providing a blueprint for future **sustainable manufacturing** approaches through feasibility study. The project's ambition is to **close this resource loop** by demonstrating how to turn these complex, non-hazardous industrial by-products and bio-based residues into the **high-value, clean chemical ingredients** needed to manufacture **sustainable plastics** and **advanced materials** right here in the UK. This creates a secure, **domestic supply chain**, strengthening the economy against global volatility. **How the project will deliver resource-efficient biomanufacturing:** the key to BioForge is its unique blend of **biology** and **digital intelligence**, which we call the "**Digital Biorefinery**". This is a completely new way of **manufacturing** that moves beyond old, energy-intensive chemical processes: * **Clean Chemistry:** We use specially selected **biocatalysts** (natural enzymes and microbial systems) to break down or convert waste molecules. This processing happens under **mild conditions, reducing material intensity and reliance on energy-intensive steps compared to** traditional methods, resulting in inherent **energy** and **cost savings**. * **Autonomous Digital Control:** The project's major innovation is an AI-based **control system** that optimises bioprocess parameters to improve yield and resource efficiency. It continuously simulates and perfects the process, learning the optimal way to control **temperature**, **concentration**, and **timing**, all in a **virtual environment**. This means we can accelerate the development of **new materials** from years to months, achieving **production efficiencies** that conventional systems cannot reach. A successful feasibility study will pave the way for **full-scale conceptual deployment**, offering significant benefits to the nation. We forecast that this technology could improve material efficiency and resource recovery by up to 40% compared with existing methods. Furthermore, by substituting **foreign imports** with secure, **domestically sourced materials**, we are pioneering a **conceptual, scalable model** that will generate hundreds of millions of pounds in annual **economic value** and create **high-skilled green jobs** across the UK. **BioForge** represents a vital step toward achieving the UK's **Net Zero** **targets**.