In the current scenario, sustainable biodiesel production strategy is used to investigate the effect of a method such different parameters of biodiesel blend viz. various load, Exhaust gas recirculation, effect of acetylene and speed on its response viz. BTE, BSFC and EGR, using Pongamia biodiesel. Anyway, the outflow is a serious issue in diesel engine in this way considering both the measure of biodiesel in mix fuel, NOx discharges get reduced in measures which can be substantially more viable. In this research, the above-mentioned different elements are utilized together, and it is important to decide the ideal conditions with regard to the performance and the emission. Initially, a test was conducted with various blends of Pongamia Methyl Ester (POME) and it was observed that B20 is the nearest to the diesel value. The B20 was taken as a base data for the purpose of comparing various loads (25%, 50%, 75% and 100%), EGR (EGR 0%, EGR 10%, EGR 20% and EGR 30%), various acetylene flow rate (11pm, 21pm, 31pm and 41pm) and speed (1200 and 1500 rpm). The trial depends on Taguchi Li6 orthogonal array symmetrical exhibit and it decided the noteworthy procedure parameters for high thermal efficiency, low specific fuel consumption and reduction of emission characteristics. It was then subjected to ANOVA analysis in order to maximize the factors of engine performance and emission characteristics. © 2023 Elsevier B.V., All rights reserved.