Plant-derived nano-bioactive systems from industrial crops: Scalable pathways toward sustainable high-value industrial products

Natural products derived from industrial crops and their byproducts constitute a vital reservoir of bioactive molecules for the agrochemical, cosmetic, pharmaceutical, and broader bio-based manufacturing sectors. Their widespread use, however, is constrained by inherent limitations, including low solubility, chemical instability, and poor bioavailability. Emerging nano-enabled delivery platforms, including nanoemulsions, solid lipid nanoparticles (SLNs), polymeric nanocapsules, nanofibers, and bioactive-loaded biopolymer films, provide transformative opportunities to enhance molecular stability, tailor release kinetics, and achieve targeted and efficient functional performance. This review critically integrates state-of-the-art progress in the formulation of plant-derived nano-bioactive systems from oilseeds, fiber crops, and cultivated medicinal and aromatic plants. Emphasis is placed on sustainable metabolite extraction technologies, green nanofabrication strategies, and their validated application potential across industrial domains. The classification framework for identifying industrial crops and residue streams is clarified, and major classes of bioactives, including terpenoids, phenolics, alkaloids, saponins, and fatty-acid-derived compounds, are systematically outlined. Key challenges and forward pathways are thoroughly discussed, particularly with respect to scalability, regulatory compliance, environmental and human health safety, and ecotoxicological assessment. Integration into circular bioeconomy models and techno-economic feasibility considerations are highlighted as essential for commercialization. Overall, this review positions plant-based nano-bioactive systems as pivotal enablers of next-generation sustainable products, accelerating industrial innovation at a global scale. • Industrial-crop nano-bioactives linked from extraction to end-use. • Green extraction aligned with nano-architectures for functional performance. • Comparative benchmarking urged against synthetic formulations. • Scale-up, safety, and regulation framed for circular bioeconomy adoption. • Research gaps identify priority industrial market entry niches.