Abstract

The essential oil industry has seen substantial growth driven by the demand for natural ingredients in food, cosmetics, pharmaceuticals, and wellness products. This review provides a comprehensive analysis of sustainable process design and cost optimization strategies in essential oil extraction. We explore conventional and emerging extraction technologies, including steam distillation, solvent extraction, supercritical fluid extraction, and microwave-assisted extraction, comparing their environmental impacts, cost-efficiency, and product quality outcomes. Emphasis is placed on optimizing resource use—energy, water, and raw materials—to reduce operational costs and environmental footprint. Additionally, process intensification strategies and green chemistry principles are discussed as frameworks for designing more sustainable extraction methods. Economic assessments indicate that while advanced methods such as supercritical CO₂ extraction incur higher initial costs, their potential for high yield, solvent recovery, and improved product purity offers long-term financial and environmental benefits. This review highlights the importance of adopting sustainable practices and technology integration for cost-effective, environmentally responsible essential oil production. The findings aim to guide industry stakeholders and researchers in implementing sustainable extraction practices that meet both economic and environmental objectives.