Revolutionizing Food Processing and Preservation through Smart and Sustainable Technologies

Rapid advances in materials science, biotechnology, digital technologies and process engineering are driving a paradigm shift in food processing and preservation, moving the sector away from energy-intensive, ‘‘one-size-fits-all’’ approaches toward precision, sustainable and consumer-centric solutions. This review synthesizes current and emerging technologies that together define the future landscape of food processing and preservation. Non-thermal and minimal-thermal technologies — including high-pressure processing (HPP), pulsed electric fields (PEF), cold plasma, ultraviolet and pulsed light, ohmic and microwave heating, and ultrasound — enable microbial inactivation and enzyme control while preserving sensory and nutritional quality. Concurrently, novel preservation strategies such as edible coatings, active and intelligent packaging, antimicrobial biopolymers, controlled and modified atmosphere systems, and natural antimicrobials (plant extracts, bacteriocins) offer targeted shelf-life extension with reduced reliance on synthetic additives. At the molecular and product-design levels, advances in synthetic biology, precision fermentation, enzyme engineering and microencapsulation are enabling tailored functional ingredients, targeted release systems and enhanced nutrient stability. Nanotechnology and smart packaging integrate nanoscale sensors and controlled-release carriers to actively monitor and respond to product quality changes. Digitalization — encompassing Internet of Things (IoT) sensors, blockchain for traceability, machine learning for process optimization and predictive shelf-life modelling — permits real-time quality control, waste reduction and supply-chain transparency. Concurrently, additive manufacturing (3D food printing) and modular micro-processing units support mass customization, on-demand manufacturing and localized production that can reduce distribution emissions. Sustainability, circular economy principles and regulatory considerations are central to technology adoption. Life-cycle impacts, energy efficiency, food safety validation, consumer acceptance and equitable access are examined as critical enablers and constraints. The review highlights integrated, hybrid approaches (combining physical, biological and digital methods) as the most promising pathway to reconcile quality, safety and sustainability goals. Key research gaps include standardized metrics for techno-economic and environmental
assessment, long-term safety evaluation of novel materials and nanoparticles, and regulatory
frameworks for biologically derived preservatives and precision-manufactured foods. The
review concludes with a roadmap for translational research, interdisciplinary collaboration and
policy actions required to accelerate responsible deployment of next-generation food
processing and preservation technologies.