Reshaping Chemical Manufacturing Towards Green Process Intensification: Recent Findings and Perspectives

The chemical industry faces major challenges despite recent progress in the transition to more environmentally friendly processes. Sustainable industrial chemistry relies on the optimization of protocols and downstream processes such as extraction, purification, and drying. Process intensification, which includes non-conventional techniques and continuous manufacturing, has emerged as a key strategy to improve efficiency and environmental impact. Technologies such as ultrasound, microwaves, mechanochemistry, and reactive extrusion offer improved performance but face scalability and proprietary barriers. Flow chemistry offers additional benefits, including smaller reactors, lower energy consumption (from 40 to 90%), and increased safety through continuous, automated reactions. However, implementing these methods requires overcoming engineering, economic, and regulatory hurdles. Biphasic catalysis and sonochemical activation in liquid–liquid systems are promising approaches for scalable reactions under mild conditions. The pharmaceutical industry, a major source of waste, has shown resistance due to high validation costs and complex regulations. Fortunately, international regulatory institutions have introduced programs to facilitate the introduction of advanced technologies. Future perspectives emphasize the integration of modular, intensified processes with digitalization and smart manufacturing. Collaborative, transdisciplinary research will be crucial for accelerating commercialization and addressing sustainability challenges in chemical production.