In an era of climate change, supply chain issues and the necessary transitions, green chemistry, green engineering and inherent safety offer possibilities for a more safe and resilient industry. A literature study with application to a pilot Organosolv lignocellulosic feedstock bioreactor should show possibilities and ways to strengthen sustainable and safer production. It highlights challenges in practical implementation like solvent selection, solvent recovery, intrinsically safe equipment and process intensification like membrane processes for saving energy. Process safety techniques should guide the way to and should help to find possible restrictions and opportunities for more resilient processes and a more resilient future. Keywords: process safety; green chemistry; organosolv; biorefinery; sustainability; solvent selection;