Abstract Bioproducts from biomass feedstocks and organic wastes have shown great potential to address challenges across food-energy-water systems. However, bioproducts production is at an early, nascent stage that requires new inventions and cost-reducing approaches to meet market needs. Biochar, a byproduct of the pyrolysis process, derived from nutrient-rich biomass feedstocks (e.g., cattle manure and poultry litter) is one of these bioproducts that has numerous applications, such as improving soil fertility and crop productivity. This study investigates the market opportunity and sustainability benefits of converting manure to biochar on-site, using a portable refinery unit. Techno-economic and environmental impact assessments are conducted on a real case study in Twin Falls, Idaho, USA. The techno-economic analysis includes a stochastic optimization model to calculate the total cost of biochar production and distribution. The environmental study employs a life cycle assessment method to evaluate the global warming potential of manure-to-biochar production and distribution network. The total cost of biochar production from cattle manure near the feedlots is approximately $237 per metric ton, and total emission is 951 kg CO2 eq. per metric ton. The on-site operation and manure moisture content are two key parameters that can reduce biochar unit price and carbon footprint of manure management. It is concluded that converting cattle manure, using the presented strategy and process near the collection sites can address upstream and midstream sustainability challenges and stimulate the biochar industry.