In response to the growing need to decarbonize industrial processes, the food sector is adopting more sustainable processing technologies aimed at reducing energy consumption, water use, and the use of chemicals. Green food processing technologies aim to improve the shelf life and nutritional value of foods through the use of physical forces, such as pressure, electric fields, and sound waves, while limiting the use of intensive heat treatments. Key solutions include high hydrostatic pressures, pulsed electric fields, ultrasound, ohmic heating, and supercritical fluid extraction. In addition to improving process efficiency, these technologies facilitate the valorization of agri-food byproducts, enabling the recovery of high-value-added compounds such as fibers, polyphenols, and prebiotics, in line with the principles of the circular economy. Despite their potential, adoption on an industrial scale remains limited. Understanding the main technical, economic, and regulatori s, as well as the factors that favor their implementation, is a crucial step toward accelerating innovation in the sector.
High hydrostatic pressures
This technology subjects foods to high pressures (100–1000 MPa) to inactivate microorganisms and enzymes without resorting to intense heat treatments. Current applications include juices and chilled beverages, sauces, ready-to-eat meat products, seafood, purees, and certain high-moisture plant-based products, with the primary goals of extending shelf life and ensuring microbiological control while maintaining sensory and nutritional quality. Currently under study or expansion are the combined use with moderate heat for spore inactivation, applications on structured plant-based products, and texture optimization in meat and plant-based products.
Electrical Technologies (PEF and Ohmic Heating)
Electrical technologies apply current directly to food to achieve preservation or controlled heating effects. Pulsed electric fields (PEF) use short-duration, high-voltage pulses to inactivate microorganisms and increase cell permeability, while also improving extraction, maceration, and juice yield. Ohmic heating, on the other hand, generates heat through the electrical resistance of the food, ensuring rapid and uniform heating. It is used in the pasteurization and sterilization of liquid and semi-solid products, with better nutrient retention and reduced thermal gradients.
Extraction with supercritical fluids
Supercritical fluid extraction is an advanced and environmentally friendly technique that uses supercritical fluids, primarily carbon dioxide (CO₂), which has lower viscosity and higher diffusivity than in its liquid or gaseous state. It can simultaneously achieve efficient extraction of targeted components and selectively extract bioactive compounds from raw materials. Unlike conventional methods based on organic or mechanical solvents, supercritical fluid extraction eliminates the need for purification steps, as it leaves no harmful solvent residues, thereby improving food safety. Operating at low temperatures and moderate pressures, it effectively preserves the bioactivity of heat-labile compounds . It demonstrates high efficiency and versatility in the extraction of a variety of phytochemicals, including flavonoids, tocopherols, essential oils, carotenoids, and fatty acids from agricultural sources and food byproducts.
Microwave thermal technology
This technology uses electromagnetic waves, at frequencies of 915 MHz or 2.45 GHz, to generate heat by rapidly vibrating water molecules and other polar compounds present in food. The process allows for rapid volumetric heat penetration, even in highly viscous foods, resulting in faster and more uniform volumetric heating compared to conventional methods. Microwave heating is currently used for pasteurization, sterilization, drying, tempering, and cooking of solid and liquid foods, as well as in pretreatment for extraction processes. Currently under study are integration with hybrid processes to improve heating uniformity, the reduction of hot/cold spots, and the use in extraction and stabilization processes for sensitive ingredients.
Foam-mat drying
Foam-mat drying is a dehydration technique that transforms liquid or semi-liquid food materials into stable foams before subjecting them to hot-air drying. This method is efficient and cost-effective for drying viscous or heat-sensitive liquid foods such as eggs, fruit juices, and vegetables. The technique promotes faster drying rates thanks to the large surface area of the foam’s porous structure, which facilitates mass transfer and allows for the use of lower drying temperatures, producing high-quality, free-flowing powders with excellent rehydration properties. Current applications include the drying of purees, juices, eggs, dairy formulations, and high-viscosity or heat-sensitive matrices, resulting in easily rehydratable powders. Industrial scaling-up, optimization of foam stability, and applications involving high-protein products and functional ingredients are currently under study.
Photonics Technologies (UV and Pulsed Light)
Light-based technologies use electromagnetic radiation for the decontamination of food and surfaces. Ultraviolet (UV) light, in the UV-A, UV-B, and UV-C s (180–400 nm), is widely used for microbial control in air, water, surfaces, and liquid products. Pulsed light, through high-intensity pulses, acts via photochemical and photothermal mechanisms, making it particularly effective for sanitizing surfaces, packaging, and dry products. Developments are focused on more efficient LED sources, greater effectiveness on complex matrices, and integration with other sanitization systems.
Ultrasonic technology
Ultrasonic technology uses high-frequency sound waves (from 20 kHz to several megahertz) to improve mass transfer rates, support thermal treatments, and modify food texture, while preserving nutritional and sensory qualities. Ultrasonic applications include cutting, freezing, drying, homogenization, emulsification, and extraction, making ultrasound a versatile and efficient tool in the food industry. Often used as a process intensification technology rather than a standalone treatment, research is underway into their use in combination with pulsed electric fields and other technologies to improve mass transfer, extraction yields, and drying processes on complex matrices.
Sustainable oxidizing solutions (ozone and electrolyzed water)
Ozone and electrolyzed water represent sustainable alternatives to traditional disinfectants. Ozone, applied in gaseous or aqueous form, is a powerful oxidizing agent that rapidly decomposes into oxygen, leaving no residue. In the U.S., ozone is authorized as an antimicrobial for the treatment, storage, and processing of food in both gaseous and aqueous forms. Electrolyzed water, obtained by the electrolysis of saline solutions, contains oxidizing species such as hypochlorous acid and is effective in removing microorganisms and contaminants from fresh produce and surfaces. Both solutions are used for sanitizing food, equipment, and process water, with a reduced environmental impact.
Cold plasma
Cold plasma technology represents the fourth state of matter, obtained by ionizing gases (air, oxygen, helium, or argon) using electrical, thermal, or electromagnetic energy. The generated plasma consists of electrons, ions, free radicals, metastable species, and UV radiation, capable of inactivating microorganisms at low temperatures due to limited heat transfer to the product. A distinction is made between quasi-equilibrium plasmas (100–150°C) and non-equilibrium plasmas (<60°C), with applications in decontamination, extending shelf life, and improving food quality, as well as in certain drying processes. Despite its strong potential, industrial adoption remains limited due to the complexity of plasma chemistry and the difficulties in controlling process parameters.
Industrial Adoption of Emerging Technologies
Despite growing interest in sustainable processing technologies, their adoption on an industrial scale remains uneven. In terms of technological maturity and industrial adoption, three distinct levels can be clearly identified: well-established and widely adopted technologies (such as high hydrostatic pressure, microwaves, UV, and ozone), solutions in the growth and progressive industrialization phase (including pulsed electric fields, ohmic heating, and ultrasound), and, finally, technologies still predominantly in the pilot or demonstration phase, such as cold plasma and some advanced applications of supercritical fluid extraction. The main drivers for adoption include improved shelf life and food safety, along with the potential to reduce energy consumption, optimize processes, and access new markets that are more focused on sustainability. Key challenges include high investment costs, the complexity of integrating these technologies into existing processes, and the need for specialized expertise. Added to these are regulatory uncertainties, often linked to complex authorization procedures, and limited consumer familiarity, which can slow down acceptance. Accelerating the adoption of these technologies therefore requires an integrated approach, including technological development, regulatory clarity, and greater communication of the benefits throughout the supply chain. In this scenario, legislation will play a decisive role in determining the speed at which these technologies spread: a clear, harmonized regulatory framework based on scientific evidence can serve as a powerful catalyst for innovation, while regulatory uncertainties, lengthy approval processes, and outdated, risk-averse approaches risk significantly slowing adoption. Alongside technological and regulatory aspects, consumer acceptance— —plays an increasingly important role: technologies perceived as “too artificial” or difficult to understand, such as electric fields, cold plasma, or advanced non-thermal treatments, may face resistance, regardless of their actual benefits in terms of safety and quality. The challenge is therefore not only technological but also communicative: making processes transparent, highlighting their concrete advantages, and building trust throughout the supply chain will be crucial to fostering their widespread adoption. For food companies, the ability to integrate technological innovation and sustainability will be a key factor in competitiveness in the coming years.
