Coconut coir waste is a rich lignocellulosic biomass. The coconut coir waste generated from temples is resistant to natural degradation, and its accumulation causes environmental pollution. Ferulic acid, a vanillin precursor, was extracted from the coconut coir waste by hydro-distillation extraction. The extracted ferulic acid was used for bio-vanillin synthesis by Bacillus aryabhattai NCIM 5503 under submerged fermentation. The process variables were optimized using the Taguchi design of the experiment. A 27 set of experimental trials was constructed with the seven most influential factors on bio-vanillin biosynthesis at three levels for the proposed experimental design. The bio-vanillin yield obtained was processed with Qualitek-4 software at bigger is better as a quality character and obtained a specific combination of factors with a predicted bio-vanillin production of 644.61 ± 0.01 mg/L. The optimal combinations of factors obtained from the proposed DOE methodology were further validated. The result revealed an enhanced bio-vanillin yield of 29.23-fold (from 495.96 ± 0.01 to 640.96 ± 0.02 mg/L) from its unoptimized condition. The extracted bio-vanillin was characterized using High-performance liquid chromatography, Fourier transform infrared, and Electrospray Ionisation Mass Spectrometry Quadrupole time-of-flight.