Green extraction and smart nanodelivery of bioactive molecules for industrial and biomedical applications

Plant-based bioactive compounds have gained considerable interest owing to their therapeutic and functional benefits in various sectors, including the food, pharmaceutical, cosmetic, and agricultural sectors. However, their real-time applications are limited due to their low solubility and decreased bioavailability. Nanotechnology has emerged as an effective strategy to improve the solubility, stability, and targeted delivery of plant-derived compounds. This review provides a comprehensive and integrated overview of recent advances in green extraction technologies and smart nanodelivery systems, highlighting their synergistic roles in improving the recovery, functionality, and industrial applicability of plant-derived bioactive molecules. Moreover, green extraction technologies, including supercritical CO₂ extraction and ultrasound- and microwave-assisted methods, are discussed. This study further explores advanced nanotechnology platforms, including nanoencapsulation systems, nanoemulsions, biopolymer-based nanoparticles, and nanostructured lipid carriers, which improve bioactive stability and delivery efficiency. Several formulation techniques, including nanoprecipitation, spray drying, freeze drying, and layer-by-layer assembly, have been addressed in relation to encapsulation efficiency, particle size, and shelf life. In addition, physicochemical, thermal, and functional characterization methods are discussed to understand nano-bioactive performance, release kinetics, and bioavailability. The major findings indicate that integrating green extraction with nanotechnology significantly enhances the extraction efficiency, physicochemical stability, bioavailability, and controlled delivery of plant bioactives, thereby facilitating their industrial and biomedical applications. Despite these advances, several challenges remain, including process scalability, long-term formulation stability, manufacturing reproducibility, regulatory approval, and commercialization issues. Future research should focus on the development of smart stimuli-responsive nanocarriers, artificial intelligence-assisted formulation design, sustainable manufacturing strategies, and circular bioeconomy approaches supported by life cycle assessments to accelerate the translation of laboratory research into commercially viable products.