Advances in Hybrid Non‐Thermal Food Processing Technologies: Mechanisms, Food Safety, Process Optimization, and Industrial Feasibility

ABSTRACT

Hybrid non‐thermal technologies are one of the emerging hurdle technologies capable of providing high quality nutritious food with microbial safety and minimum processing. These technologies are the promising alternative to traditional thermal processing for food preservation. The most effective non‐thermal technologies studied extensively include high‐pressure processing (HPP), pulsed electric fields (PEF), ultrasonication (US), and cold plasma (CP). Combination of existing non‐thermal processing technologies is termed as “hybrid”, which have profound effects on synergism thereby enhancing process efficiency and spreading wide applicability. This review comprehensively analyses current advancements in hybrid non‐thermal food processing technologies, with a focus on synergistic effects of hybrid techniques on food quality and preservation, engineering design, microbial inactivation, nutrient delivery, process modeling, scale‐up and industrial feasibility. The elemental mechanisms of individual non‐thermal technologies jointly with hybrid effects on microbial inactivation, suppression of enzyme activity, and extended mass transfer are elaborated alongside strategies for system configuration and process integration. The major focus has also been given to the role and function of hybrid non‐thermal technologies in functional food delivery incorporating bioavailability, retention, and homogeneous distribution of functional agents such as micronutrients, probiotics, and others. It also systematically reviews and addresses inactivation kinetics of pathogen and spoilage‐causing microbes while unaltering beneficial microflora inside the system. The limitations in scaling up, process modeling gaps, and techno‐economic considerations are discussed to understand industrial feasibility. Ultimately, future research directions are suggested for the adoption of hybrid non‐thermal processing technologies in value addition, functionalization, and advanced food preservation systems.