Green Extraction at Scale: Hydrodynamic Cavitation for Bioactive Recovery and Protein Functionalization—A Narrative Review

Hydrodynamic cavitation (HC) is a green and readily scalable platform for the recovery and upgrading of bioactives from agri-food and forestry byproducts. This expert-led narrative review examines HC processing of citrus and pomegranate peels, softwoods, and plant protein systems, emphasizing process performance, ingredient functionality, and realistic routes to market, and contrasts HC with other green extraction technologies. Pilot-scale evidence repeatedly supports water-only operation with high solids and short residence times; in most practical deployments, energy demand is dominated by downstream water removal rather than the extraction step itself, which favors low water-to-biomass ratios. A distinctive outcome of HC is the spontaneous formation of stable pectin-flavonoid-terpene phytocomplexes with improved apparent solubility and bioaccessibility, and early studies indicate that HC may also facilitate protein-polyphenol complexation while lowering anti-nutritional factors. Two translational pathways appear near term: (i) blending HC-derived dry extracts with commercial dry protein isolates to deliver measurable functional benefits at low inclusion levels and (ii) HC-based extraction of plant proteins to obtain digestion-friendly isolates and conjugate-ready ingredients. Priority gaps include harmonized reporting of specific energy consumption and operating metrics, explicit solvent/byproduct mass balances, matched-scale benchmarking against subcritical water extraction and pulsed electric field, and evidence from continuous multi-ton operation. Overall, HC is a strong candidate unit operation for circular biorefineries, provided that energy accounting, quality retention, and regulatory documentation are handled rigorously.