Ultra-high molecular weight polyethylene (UHMWPE) remains a flagship material among high-performance polyolefins,yet its future is increasingly governed by the competing demands of large-scale manufacturability and environmental responsibility. This review surveys recent advances in UHMWPE fiber processing with an emphasis on the transition from conventional batch dissolution to continuous, high-throughput twin-screw extrusion (TSE) routes for gel-spinning dopes. Particular attention is given to the impact of ultra-long screw length-to-diameter (L/D) configurations (up to 136), which markedly promote chain disentanglement and have been shown to deliver gains in tensile strength approaching 150% and increases in gel crystallinity of roughly 50% relative to standard industrial L/D ≈ 36 designs. In parallel, we critically assess emerging “green” processing strategies, including the adoption of bio-derived terpene solvents and supercritical CO₂ (scCO₂)–based extraction and washing schemes. Reported scCO₂ washing protocols reduce global warming potential by a factor of about 2.4 and cut overall carbon footprint by more than half compared with conventional n-hexane extraction. By integrating insights from polymer physics with process engineering and life-cycle considerations, this review benchmarks these developments against incumbent commercial UHMWPE fibers such as Dyneema® and Spectra®,and outlines prospective directions for next-generation high-tenacity fibers in marine, defense, and biomedical applications.