Innovative Applications of Sugarcane Bagasse in the Global Sugarcane Industry

Sugarcane bagasse (SCB), a major byproduct of the sugar industry produced in millions of tons annually, is traditionally burned for energy but holds untapped potential for sustainable valorization amid global shifts toward renewable resources and reduced fossil fuel reliance. This review synthesizes recent advancements in SCB applications beyond energy, emphasizing bioenergy, bioplastics, construction materials, and agriculture to advance circular economy principles—addressing a gap in the existing literature by providing a holistic, comparative analysis of processing technologies, including their efficiency, costs, and scalability, which prior reviews have overlooked. Drawing from scientific literature, industry reports, case studies, and datasets, we evaluate SCB’s composition (40–50% cellulose, 25–30% hemicellulose, 20–25% lignin) and processing methods (e.g., pretreatment, hydrolysis, gasification, pyrolysis). Key findings highlight versatile applications: bioethanol production yielding 40–70% GHG reductions per life cycle assessments; pulp/paper substitution reducing water and chemical use; nanocellulose composites for automotive and medical sectors; particleboard and ash-cement in construction cutting deforestation and carbon footprints by ~20%; and biochar/processed feed enhancing crop yields by 25% while amending soil. Unlike previous reviews focused on isolated applications, this work integrates environmental, economic, and regulatory insights, identifying challenges like standardization gaps and proposing pathways for commercialization to drive scalable, green industry transitions. Continued research and policy support are essential for realizing SCB’s role in sustainable development.