Reactive Extrusion for Sustainable Biomaterials and High-Value Applications

Dear Colleagues,

The global imperative to transition towards a circular bioeconomy and mitigate the ecological impact of conventional materials has catalyzed a paradigm shift in materials science and process engineering. In this context, the development of sustainable, high-performance biomaterials from renewable feedstocks is not merely an incremental improvement but a foundational necessity for future industrial viability.

At the vanguard of this transformation lies reactive extrusion (REX), a process-intensified technology that uniquely integrates chemical synthesis and polymer processing within a single, continuous operation. By enabling in situ polymerization, grafting, and functionalization of biopolymers, REX offers a substantial improvement in resource efficiency, atom economy, and energy consumption over traditional multi-stage batch processes. This technology represents a critical nexus where chemical engineering, polymer science, and green chemistry converge, providing a robust platform for the valorization of biomass and the creation of novel functional materials that are both economically competitive and environmentally benign.

This Special Issue aims to serve as a definitive scholarly forum, consolidating cutting-edge research that bridges the fundamental principles of reactive extrusion with its practical application in creating the next generation of sustainable biomaterials. The scientific importance of this collection lies in its potential to accelerate the displacement of petroleum-derived products by systematically addressing the core technical challenges that currently impede the widespread commercialization of biomaterials. We particularly encourage submissions that delve into the complex interplay of reaction kinetics, rheology, and transport phenomena through advanced modeling and in-line characterization, as these are the critical pillars upon which process optimization and industrial scalability are built.

We believe that a focused compilation of high-impact research in this domain will not only document the state-of-the-art but also catalyze future innovation, fostering the interdisciplinary collaborations necessary to translate laboratory-scale discoveries into industrially relevant technologies. Your contribution is vital to building a comprehensive body of work that will guide future research and development in sustainable manufacturing.

We cordially invite you to submit your original research articles, comprehensive reviews, and forward-looking perspective pieces on a range of topics, including but not limited to:

(1) Fundamental Science & Engineering:

• Rheology and Modeling of Complex Reactive Extrusion Systems
• Advanced In situ and Ex situ Characterization Techniques for Commercial Scale-Up
• Reaction Kinetics and Mechanisms in Solvent-Free Extrusion Environments

(2) Sustainable Materials & Composites:

• Development of Advanced Biocomposites for Agriculture, Pulp and Paper, and Food Industries
• Creation of Eco-Friendly Packaging and Personal Care Products from Extruded Biomaterials
• Reactive Extrusion for Waste Biomass Conversion into High-Value Materials

(3) Circular Bioeconomy & Applications:

• Valorization of Biomass for Bioenergy and Clean Label Ingredients via Reactive Extrusion
• Integration of Reactive Extrusion in Circular Economy and Biorefinery Frameworks
• Innovative Applications in Sustainable Consumer Products and High-Value Chemical Intermediates

(4) Techno-Economics & Impact Assessment:

• Life Cycle Assessment (LCA) of Reactively Extruded Sustainable Products
• Techno-Economic Analysis (TEA) and Industrial Implementation of REX Processes
• Scalability Challenges and Solutions for Continuous Reactive Extrusion

We look forward to receiving your esteemed contributions to this timely and impactful Special Issue.

Dr. Ali Ayoub
Guest Editor

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sustainability is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

• extrusion
• bioplastics
• food processing
• composite
• blending
• biomanufacturing