BACKGROUND: An improved resilient back-propagation neural network modeling coupled with genetic algorithm aided optimization technique was employed for optimizing the process variables to maximize lipopeptide biosurfactant production by marine Bacillus circulans. RESULTS: An artificial neural network (ANN) was used to develop a non-linear model based on a 24 full factorial central composite design involving four independent parameters, agitation, aeration, temperature and pH with biosurfactant concentration as the process output. The polynomial model was optimized to maximize lipopeptide biosurfactants concentration using a genetic algorithm (GA). The ranges and levels of these critical process parameters were determined through single-factor-at-a-time experimental strategy. Improved ANN-GA modeling and optimization were performed using MATLAB v.7.6 and the experimental design was obtained using Design Expert v.7.0. The ANN model was developed using the advanced neural network architecture called resilient back-propagation algorithm. CONCLUSION: Process optimization for maximum production of marine microbial surfactant involving ANN-GA aided experimental modeling and optimization was successfully carried out as the predicted optimal conditions were well validated by performing actual fermentation experiments. Approximately 52% enhancement in biosurfactant concentration was achieved using the above-mentioned optimization strategy. (c) 2012 Society of Chemical Industry