In recent years, the use of xylanases has been adopted by many processing industries, such as pulp and paper, food and textile factories. This study demonstrates that Thermoascus aurantiacus ATCC 204492 is able to produce a high level of thermostable xylanase when sugar cane bagasse is used as a substrate. Fermentations were performed in a glass-column reactor with forced aeration. A xylanase activity of 1597 U/g was attained after 10 days of solid-state fermentation. The effects of different airflow rates (0, 3.0, 6.0 l/(h g) bagasse) and initial mass of bagasse (8, 12.5, 17 g) on the production of xylanase were investigated using a statistical experimental design. The airflow rates had a significant effect on enzyme activity, whereas initial mass of bagasse had no significant effect on enzyme activity. 6 l/(h g) airflow rate and 8 g substrate resulted in the highest yields of xylanase (1597 U/g). (C) 2003 Elsevier Ltd. All rights reserved.