Integrated processing of agro-industrial by-products into functional bioactive ingredients for sustainable food and health applications

Abstract Agro-industrial by-products have emerged as strategic and sustainable sources of bioactive compounds; however, the transition from laboratory-scale recovery to industrially viable functional ingredients remains limited by challenges associated with extraction selectivity, compound instability, low bioavailability, process integration, and regulatory uncertainty. Although numerous reviews address isolated recovery or stabilization technologies, a critical discussion integrating extraction, encapsulation, and drying as interconnected stages within a unified valorization platform remains lacking. Therefore, this review critically evaluates recent works (2021–2025) in processing strategies for the recovery, stabilization, and application of bioactive compounds derived from fruit and vegetable agro-industrial residues. Particular emphasis is placed on how process interdependency influences extraction efficiency, encapsulation performance, drying stability, release kinetics, bioaccessibility, and industrial applicability. The transition from conventional extraction methods toward sustainable technologies, including ultrasound-assisted extraction, microwave-assisted extraction, supercritical fluids, and deep eutectic solvents, combined with advanced encapsulation and drying systems, is critically discussed in terms of scalability, energy demand, operational limitations, and preservation of bioactive compounds. Comparative analysis of recent studies demonstrates that the effectiveness of valorization strategies depends not only on bioactive recovery yields, but also on matrix composition, extraction selectivity, encapsulation efficiency, drying conditions, and stabilization technologies capable of maintaining functionality throughout processing, storage, and application. This review discusses industrial translation challenges involving raw material variability, process standardization, economic feasibility, regulatory approval, and large-scale implementation. Future advances in this field will depend on the development of scalable integrated bioprocessing platforms aligned with circular bioeconomy principles and capable of generating stable, safe, and high-value ingredients for food, nutraceutical, cosmetic, and animal health applications.