This work employed a systematic methodology and process intensification concepts to improve the state-of-the-art vanillin production process from kraft lignin. Particular focus was put on the use of different product separation techniques, including solvent extraction using ethyl acetate, benzene, organic nanofiltration, and adsorption by zeolite. The performance of each proposed process was evaluated in terms of energy consumption, process economics, and environmental impacts. Simulation of the vanillin production processes was performed using the Aspen Plus program while the economic and environmental analyses were conducted using economic analysis tools and LCSoft, respectively. The results revealed that the process using adsorption by zeolite is the best alternative. It offered a slight improvement in energy consumption while its economic result showed 7.37% improvement. It also caused the least environmental impact in all categories. (C) 2018 Elsevier Ltd. All rights reserved.