In the searching for alternative, more sustainable ingredients for food sector, this study tackled the production of an oil derived from Tenebrio molitor (TM) by means of supercritical carbon dioxide (scCO2) technology. Kinetic curves recorded by bench scale (BS) experiments assessed parameters as particle size distribution or the use of modifiers solvents (ethanol) in the supercritical phase, revealing a maximum degree of defatting above 90 %. While operations at pilot plant (up to 5.5 kg of TM) still afforded a distinguished yield (84 % defatting) by ruling out the use of doping agents. The produced oil at this level of operation showed a noticeable proportion of unsaturated fat (41 % oleic acid and 30 % linoleic acid) and a more than acceptable freshness being evaluated through peroxide index (15 meq O2/kg oil) or acidity degree (2 %), which suggests the applicability of this oil as a novel food. To test the real suitability of this methodology, an environmental impact evaluation was conducted on pilot scale processes. Green chemistry performance metrics (GCPMs) revealed low environmental factor (EF, 0.19), high process mass productivity (PMP, 84.21 %) and eco-scale (83.10). Further, a Life-cycle Assessment (LCA) displayed an impact reduction in categories such as stratospheric ozone depletion, marine and freshwater eutrophication, and land use compared to the production of 1 kg of palm and soybean oil. Overall, the use of advanced technologies for process intensification, together with the process balance and sustainability, as well as the quality of the recovered product support the adoption of this protocol for its implementation in the food sector.