Between 2007 and 2010 DuPont conducted a program under DOE award DE-FC36-07GO17056 to develop and improve Zymomonas mobilis as an ethanologen for commercial use in biorefineries to produce cellulosic ethanol. This program followed upon an earlier DOE funded program in which DuPont, in collaboration with the National Renewable Energy Laboratory (NREL) had developed a Zymomonas strain in conjunction with the development of an integrated cellulosic ethanol process. In the current project, we sought to maximize the utility of Zymomonas by adding the pathway to allow fermentation of the minor sugar arabinose, improve the utilization of xylose, improve tolerance to process hydrolysate and reduce the cost of producing the ethanologen. We undertook four major work streams to address these tasks, employing a range of approaches including genetic engineering, adaptation, metabolite and pathway analysis and fermentation process development. Through this project, we have developed a series of strains with improved characteristics versus the starting strain, and demonstrated robust scalability to at least the 200L scale. By a combination of improved ethanol fermentation yield and titer as well as reduced seed train costs, we have been able to reduce the capital investment and minimum ethanol selling price (MESP) by approximately 8.5% and 11% respectively vs. our starting point. Furthermore, the new strains we have developed, coupled with the learnings of this program, provide a platform for further strain improvements and advancement of cellulosic ethanol technology.