This work presents a comprehensive review of the evolution in modeling reactive extrusion (REx), tracing developments from early analytical models to advanced computational fluid dynamics (CFD) simulations. Additionally, it highlights the key challenges and future directions in this field. Analytical models to describe the velocity profiles were proposed in the 1950s, involving certain geometrical simplifications. However, numerical models of melt polymeric flow in extruders have proven to be crucial for optimizing screw design and predicting process characteristics. The state-of-the-art CFD models for single and twin-screw extruders design address the impact of geometry (type of mixing elements and geometrical simplifications of CFD geometries), pressure and temperature gradients, and quantification of mixing. Despite the extensive work conducted, modeling reactive extrusion using CFD remains challenging due to the intricate interplay of mixing, heat transfer, chemical reactions, and non-Newtonian fluid behavior under high shear and temperature gradients. These challenges are further intensified by the presence of multiphase flows and the complexity of extruder geometries. Future advancements should enhance simulation accuracy, incorporate multiphase flow models, and utilize real-time sensor data for adaptive modeling approaches.

Vegetable supply in the world is more than double than vegetable intake, which supposes a significant waste of vegetables, in addition to the agricultural residues produced. As sensitive food products, the reasons for this waste vary from the use of only a part of the vegetable due to its different properties to the product appearance and market image. An alternative high-added-value application for these wastes rich in cellulose could be the reduction in size to produce lignocellulose micro- and nanofibrils (LCMNF). In this sense, a direct treatment of greengrocery waste (leek, lettuce, and artichoke) to produce LCMNFs without the extraction of cellulose has been studied, obtaining highly concentrated suspensions, without using chemicals. After drying the wastes, these suspensions were produced by milling and blending at high shear followed by several passes in the high-pressure homogenizer (up to six passes). The presence of more extractives and shorter fiber lengths allowed the obtention of 5–5.5% leek LCMNF suspensions and 3.5–4% lettuce LCMNF suspensions, whereas for artichoke, only suspensions of under 1% were obtained. The main novelty of the work was the obtention of a high concentration of micro- and nanofiber suspension from the total waste without any pretreatment. These high concentrations are not obtained from other raw materials (wood or annual plants) due to the clogging of the homogenizer, requiring the dilution of the sample up to 1% or the use of chemical pretreatments.