Yuehua Chen, Bin Li, Xiaohu Guo, Shiguo Wang, Yang Liu, Zhong Tang
With the expansion of modern protected agriculture, the amount of post-harvest tomato biomass has increased sharply. Conventional unmanaged disposal practices disrupt carbon flows and cause substantial environmental emissions. Tomato plant residues (TPRs), which are rich in lignocellulose and selected high-value secondary metabolites, have considerable potential as feedstocks for green industrial materials. However, their complex biophysical properties, high physiological moisture content, and recalcitrant cell-wall barriers hinder large-scale processing. This review systematically examines the mechanisms and process architectures for converting TPRs into macromolecular products. First, it analyzes cross-scale anatomical heterogeneity and dynamic rheological properties of TPRs, defining their physicochemical boundaries as industrial precursors. Second, it summarizes the development of physical field-coupled equipment, ranging from anti-tangling harvest-shredding to die-roller densification. Furthermore, it examines the core mechanisms of multi-field-coupled pretreatment technologies, including steam explosion, deep eutectic solvents (DES), and mechanochemistry, in deconstructing vascular skeletons and reducing multiphase mass-transfer resistance. Finally, this review discusses reconstruction pathways for TPR-derived components in advanced polymer materials, including biodegradable nanocellulose films, bio-based composites, aerogels, and lignin-based polyurethane networks. Overall, it links microscopic reaction kinetics with macroscopic equipment engineering, proposes a closed-loop material conversion system from in-field volume reduction to cascaded biorefinery, and provides an engineering framework for future multi-machine intelligent collaboration and continuous production across the industrial chain.