Mechanistic kinetic modeling and green extraction technology for the valorization of plant bioactive compounds

To meet the rising industrial demand for natural, functional ingredients, there is an urgent shift away from traditional methods toward sustainable, efficient extraction technologies. Conventional extraction methods, although well-established, are often associated with excessive solvent consumption, high energy demand, lengthy processing times, and degradation of heat-sensitive compounds. In this context, green extraction technologies have emerged as promising alternatives that comply with the principles of green chemistry and sustainable processing. Aiming to promote sustainability in bioactive recovery, this paper examines the latest breakthroughs in green extraction applied to plant-based materials and agro-industrial by-products. The discussion centers on advanced technological frameworks, including microwave- and ultrasound-assisted methods, pressurized liquid and supercritical fluid systems, and novel approaches such as cloud point extraction. Particular emphasis is placed on extraction kinetics and mathematical modeling to elucidate mass-transfer phenomena and support process optimization and scale-up. The manuscript further highlights applications of green extraction in functional foods, nutraceuticals, cosmetics, and biomass valorization within a circular bioeconomy framework. Current challenges, including scalability, solvent recovery, regulatory acceptance, and economic feasibility, are discussed, and future perspectives are proposed to facilitate the industrial implementation of green extraction technologies.