Biosurfactants encompass a number of structurally and chemically diverse compounds, all of which demonstrate surface active properties. The potential and current application of these compounds ranges from enhanced oil recovery, through detergents, emulsifiers in foods, antifungal agents, antibiotics, and even to uses in the minerals processing industry. And while the market demand for these products is growing, the industry still is significantly smaller than the synthetic surfactants market. Part of the reason for this is that biosurfactants are currently comparatively expensive to produce. This article reviews the process consideration steps required to develop a biosurfactant bioprocess (organism selection and modification, reactor type and operation, media, downstream processing, and final use) and considers the state of the art of each process step, with an eye to considering the overall process development, and establishment of both technically and economically viable routes to production.