The aim of this manuscript is to present an integrated process that includes reaction and separation steps for producing vanillin and lignin-based polyurethanes from Kraft lignin. it provides details about lignin oxidation and subsequent vanillin recovery, as well as, the synthesis of lignin-based polyurethanes. The oxidation of Kraft lignin in alkaline medium has been carried out in a batch reactor and the optimum operational conditions for vanillin production obtained. The feasibility of a continuous process for vanillin production has been analyzed using a structured bubble column reactor. The generated reaction stream (degraded lignin and sodium vanillate) was further subjected to an ultrafiltration process to recover the vanillate. An ion-exchange process allows recovering the vanillin by passing the vanillate solution through a column packed with an ion-exchange resin in H+ form. The remaining lignin can act as a raw material to produce polyurethanes and/or biofuels. In this work the first approach was explored. (C) 2009 The Institution of Chemical Engineers. Published by Elsevier B.V All rights reserved.