Pullulan is a water‐soluble polysaccharide produced through fermentation with
Aureobasidium pullulans
. Pullulan has been used as specialty food for decades in Japan. Owing to its relatively high price, recent developments on pullulan are mainly focused on its application in biomedical engineering and pharmaceutical industry. Both laboratory and commercial pullulan production methods are reviewed. Among several problems associated with pullulan fermentation, the highly viscous fermentation broth remains the biggest challenge. The viscous non‐Newtonian broth creates major difficulties in mixing, oxygenation, process monitoring, sampling, and downstream product recovery. Many approaches to improve the fermentation efficiency have been attempted. One promising method is to use close clearance impellers, such as reciprocating plate mixer, instead of standard Rushton turbines in order to achieve more uniform mixing. Other unconventional techniques, such as cell immobilization, hyperbaric fermentation, and nonsterile fermentation, have also been discussed. However, these technologies need more research and investigation before they can be implemented at an industrial scale.