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The development of biomass-based cogeneration energy systems in Malaysia is progressing to meet the circular economy concept and sustainability goal. This comprehensive review aims to report recent advancements in biomass-based cogeneration/biomass co-firing technology in Malaysia correlated with the optimization modeling role. First, this work presents the outlook and current scenario of cogeneration systems in Malaysia by observing performance and the challenges confronted by the technologies. Next, investigation of technical issues concerning the key players of the technologies and the biomass supply chain. This work had prepared using quantitative content-based analysis-meta-analysis. The practical implication of this review enables a complex optimization model that integrates biomass-based cogeneration and biomass supply chain considering economic and environmental viability. It will further enhance progress toward the Malaysian "Industry 4.0-driven" energy initiative. A novel optimization model grounded on Industry 4.0 parameters will foster new opportunities for researchers. [Display omitted] • The biomass cogeneration outlook, current scenario, successes and regional challenges in Malaysia. • Technical and operational issues of the biomass based-cogeneration and biomass co-firing. • Role of optimization modeling in the biomass based-cogeneration, biomass co-firing and biomass supply chain advancements. • New directions and the potential of those technologies in the era of Industry 4.0 [ABSTRACT FROM AUTHOR]