Advances in Hybrid Thermal and Non-Thermal Processing Techniques for Sustainable Food Preservation: A Narrative Review
D. Kalpana *
Department of Agricultural Engineering, College of Agriculture, PJTAU, Rajendranagar, Hyderabad, Telangana, India.
Samreen
College of Food Science and Technology, PJTAU, Rudrur, Nizamabad, Telangana, India.
*Author to whom correspondence should be addressed.
Abstract
Global food systems are challenged by population growth, climate variability, and consumer demand for minimally processed foods with longer shelf life and high nutritional quality. Conventional thermal processing effectively controls microbes but often reduces bioactive compounds, sensory attributes, and energy efficiency. Non-thermal technologies such as high hydrostatic pressure, pulsed electric fields, ultrasound, cold plasma, and ultraviolet light offer promising alternatives at near-ambient temperatures. However, individual technologies have limitations in microbial inactivation, throughput, and cost. Hybrid processing approaches combining thermal and non-thermal methods have gained attention for enhancing preservation efficiency while reducing energy use and maintaining product quality. This narrative review synthesises the current state of knowledge on the mechanisms, efficacy, sustainability performance, and industrial applicability of hybrid thermal and non-thermal processing techniques. Evidence drawn from peer-reviewed literature published between 2000 and March 2026 indicates that well-designed hybrid systems can achieve equivalent or superior microbial inactivation relative to single-technology processes, with concomitant improvements in energy efficiency and bioactive compound retention. The review further examines the regulatory landscape governing novel processing technologies, identifies critical gaps in industrial scalability and life-cycle assessment methodology, and outlines future research priorities. It is concluded that hybrid processing represents a scientifically coherent and commercially viable pathway towards sustainable food preservation, contingent upon advances in real-time process monitoring, adaptive control systems, and evidence-based regulatory harmonisation. The economic feasibility of hybrid food processing is improving due to declining equipment costs, growing market demand for clean-label products, and enhanced operational reliability through engineering advancements. Hybrid thermal and non-thermal technologies are emerging as a scientifically promising and commercially important approach for simultaneously improving food safety, nutritional quality, sustainability, and resilience within modern food systems.
Keywords: High hydrostatic pressure, pulsed electric fields, thermosonication, cold atmospheric plasma, ohmic heating, hybrid food processing, sustainable preservation, hurdle technology, food safety, non-thermal processing