Abstract The objective of this article is to design and plan sustainable bio-ethanol supply chain. Modeling supply chains that achieve economic, social and environmental feasibility through production, process and energy efficiency is a challenge. Life cycle assessment that is coupled with techno-economic optimization of bio-ethanol supply chain is an alternative solution to achieve sustainability. A simulation of the biomass conversion is used to find process parameters of the conversion technology. The results show that the unified model is capable of minimizing both CO 2 emissions and energy and utility consumptions. In addition, the supply chain is capable of contributing to local economy through jobs creation. While the model is quite comprehensive, the future research recommendation on energy integration and global sustainability is proposed.