International Journal of Chemical Studies 2018; 6(6): 770-776

P-ISSN: 2349–8528
E-ISSN: 2321–4902
IJCS 2018; 6(6): 770-776 Novel food processing technologies: An overview
© 2018 IJCS
Received: 09-09-2018
Accepted: 13-10-2018
Fozia Hameed, Anjum Ayoub and Neeraj Gupta
Fozia Hameed
Research Scholar Division of Abstract
Food science and Technology Novel food processing technologies arose as a result of consumer’s desire for safe, tasty, fresh and mild
SKUAST Chatha Jammu, processed food products with long shelf life and maintained quality. Recent trend of lifestyle changes, as
Jammu and Kashmir, India consumers demand products with a significant nutritional contribution, bioactive compounds, and good
sensory properties, posed a great challenge toward food processing sector for the evolution of novel and
Anjum Ayoub innovative food processing techniques. The novel food processing technologies, viz. HPP, PEF,
Research Scholar Division of Irradiation, ultrasonication and cold plasma which influence on consumer’s health have been the major
Food science and Technology innovations in the field of processing technology. These novel techniques act by prolonging the shelf life,
SKUAST Chatha Jammu, enhancing or maintaining the quality, and to regulate freshness of food product. The main objectives of
Jammu and Kashmir, India this review article are to provide basic knowledge of different new and innovative food processing
techniques about their way of preservative action, effectiveness and suitability in various types of foods.
Neeraj Gupta
Assistant Professor Division of
Food science and Technology Keywords: innovative, shelf life, processing, quality, bioactive
SKUAST Chatha Jammu,
Jammu and Kashmir, India Introduction
Novelty and recent trends in food processing techniques are the result of consumer demand for
health promoting foods with high nutritional and nutraceutical values (Bagchi, 2008) [4]. Since
ancient times, the approach of the food industry was to provide safe food product with long
shelf-life; however, presently it is not enough to simply produce safer food as consumers
demand products with a significant nutritional contribution, bioactive compounds, and good
sensory properties. The important food quality attributes, such as taste, texture, appearance,
and nutritional value, are strongly dependent on the way food is processed (Knoerzer et al.,
2016) [27]. Microorganisms are the main target organisms for food spoilage and poisoning so
are targeted by different food preservation procedures. Food processing methods used by
industry rely either on microbial inactivation or inhibition of microbial growth. Conventional
heat-dependent pathogen-reduction methods such as thermization, pasteurization and in-
container sterilization can adversely affect taste, nutritional value and appearance. Alternative
techniques for traditional thermal processing of food have received much interest, due to
increased consumer demand to deliver higher quality and better consumer-targeted food
products, many innovative food processing techniques called “novel” or “emerging”
techniques have been developed. Several novel processing techniques recently introduced; in
particular, were high pressure processing (HPP), pulsed electric field (PEF), ultrasonic,
irradiation, cold plasma, hydrodynamic cavitation etc (Knorr et al., 2011) [28]. Additionally,
food products processed through these innovative techniques contribute to global food security
by extending shelf life (Knoerzer, et al., 2015) [26]. This review aims to describe the basic
principles, mechanism of action and applications of some of these emerging technologies.

Novel food processing technologies

Thermal processing is commonly used to extend the shelf-life and to ensure the
microbiological safety of food products because of its ability to inactivate microorganisms and
spoilage enzymes (Rawson et al., 2011) [50]. However, thermal processing can cause
detrimental effects on the quality and nutritional values of the fruit-based commercial
products. The constituents responsible for color, flavor and taste are typically heat-sensitive, so
Correspondence thermal processing can easily change the quality of the commercial fruit products and affect
Fozia Hameed product acceptability (Gao et al., 2016) [18]. Thus, the search for alternative methods for
Research Scholar Division of thermal food processing which would generate a safer product with higher quality, nutrient
Food science and Technology content and sensorial properties incited food scientists to explore other inactivation techniques.
SKUAST Chatha Jammu,
Jammu and Kashmir, India
Two broad fields of food processing technologies are currently under research, non-thermal

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technologies, in which the inactivation factor is by physical et al., 2017) [30]. Hence, HPP allows better retention of
hurdles such as pressure, electromagnetic fields, and sound nutritional values and sensory properties than the traditional
waves, among others; and novel thermal processing pasteurization technologies. HPP has been successfully
technologies, which mainly use energy generated by employed to preserve blueberry juice (Barba et al., 2012) [7],
microwave and radio frequency. However, using such novel strawberry and its puree (Gao et al., 2016; Marszałek et al.,
technologies to inactivate microorganisms and enzymes in 2017) [18, 33], pawpaw pulp (Zhang et al, 2017) [56], apple
food is not enough. A safer product should also be free of juices (Nayak et al, 2017) [42], cantaloupe puree
poisonous substances and contact of food with certain (Mukhopadhyay et al., 2017) [39], grape juice (Chang et al,
materials during processing should be avoided (Lelieveld & 2017) [10], and so on, extending their shelf-life in 10–60 days
Keener, 2007) [31]. Thus, evaluation of the overall quality of range.
food products processed by innovative technologies is an
essential requirement before a product can be Principle
commercialized. Pascalisation is based actually on activation volume that uses
a transferring medium and is applied only in batch processing
Novel food processing technologies around the world units. HPP is based on the Le Chatelier’s principle indicating
Non thermal technologies that an application of pressure shifts the systems equilibrium
to the state that occupies the lowest volume. Therefore any
Non thermal technologies Thermal technologies chemical or physical changes (phase transitions, chemical
High hydrostatic pressure microwave reactions and changes in molecular configuration)
Pulsed electric fields Radio frequency accompanied by decrease in volume are enhanced by the
Irradiation Ohmic heating application of pressure. Consequently non-covalent bonds are
Ultrasound Inductive heating affected while key food quality parameters remain mostly
Cold plasma unchanged. However, enzyme reactions can occur (e.g. during
Ozone pressure build up phase before inactivation), adiabatic heating
Supercritical water
takes place (approx. 1-2 °C per 100 MPa) and temperature
and pressure distribution is not entirely homogenous in
It is worth mentioning that most novel technologies were first processing units.
studied as prospective microbial inactivation technologies to
improve the safety of food. However, important results in the Mechanism of microbial inactivation
final characteristics of many food items were also observed: Significant research has been conducted to show the
such as intact nutrient content in most of the novel food inactivation of microorganisms by the application of high
products; unique sensorial properties like color, texture, and hydrostatic pressure in foods (Donaghy et al., 2007) [12]. The
appearance; and formation of new aroma compounds. Thus, efficiency of HPP to inactivate microorganisms is dependent
the search for microbial inactivation technologies not only on the target pressure, process temperature, and HT. The
yielded the possibility of a safer product, but also improved relationship between pressure and temperature in a typical
overall product quality, and provided new ingredients for the HHP was described by (Muntean et al., 2016) [41]. Different
development of other novel food products. microorganisms react with different degrees of resistance to
HPP treatment and most of the vegetative microorganisms,
High pressure processing yeasts, and viruses can be inactivated at or near room
High pressure processing (HPP) is one of the promising non- temperatures. On the other hand, bacterial spores are
thermal preservation techniques and has proven to be an extensively resistant to high hydrostatic pressures and for the
effective alternative to conventional food preservation mold sterilization, a combination of pressure (400-600 MPa)
technologies to enhance safety and shelf life of perishable and heat (90-120 °C) is often required. Furthermore the
foods (Balasubramaniam and Farkas, 2008) [5] with minimal pressure sensitivity of the bacterial cells also depends on the
influence on the sensory, physical, and nutritional properties growth phase. Bacterial cells in the stationary growth phase
of foods. High pressure processing (HPP) also referred to as are generally more resistant to pressure than those in the
ultra high pressure UHP) or high hydrostatic pressure (HHP) exponential growth phase (Hayman et al., 2007) [21]. For the
is the application of elevated hydrostatic pressures of 150 to inactivation of vegetative pathogenic and spoilage
700 MPa for 30 s to inactivate spoilage and pathogenic microorganisms, HPP pasteurization demands a logarithmic
microorganisms, with the aim of obtaining microbiologically reduction of 5 or 6 in pathogens at chilled or process
safe food products while avoiding undesirable changes in the temperatures less than 45 °C and at pressures above 200 MPa.
sensory, physicochemical and nutritional properties of food
(Munoz et al, 2007) [40]. Pressure generation is mechanical
usually through a fluid (water) which is consequently
transmitted to the product. While transmission of pressure is
typically thought to be isostatic and near-instantaneous, the
inactivation of pathogens requires a prolonged hold at high
pressure. This introduces special challenges to manufacturers,
because of the substantially high equipment and maintenance
costs and possible damage to product quality
(Balasubramaniam and Farkas, 2008) [5].
HPP induces less impact on the low molecular weight
nutrients such as vitamins and polyphenols, and compounds
related to sensory properties such as pigments and flavoring
agents compared with conventional thermal processing (Landl Pressure, Temperature, and Time during a HPP process
(Ferstl, 2013).
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The response of the microorganisms largely depends on the (i) Initial stage (with the duration from nanoseconds to
substrate and food composition during the pressure treatment. milliseconds): creation of pores when an electric pulse is
On applying pressure following detrimental changes take applied (electroporation)
place that results in the microbial cell destruction: (ii) Stage of evolution of the pore population (with the
 Irreversible structural changes of the membrane proteins duration from nanoseconds to milliseconds): change in
and other macromolecules, leading to disruption of cell the number of pores and their sizes during an electric
membrane (Muntean et al., 2016) [41]. treatment.
 Destruction of homogeneity of the intermediate layer (iii) Post-treatment stage (with the duration from miliseconds
between the cell wall and the cytoplasmic membrane. to hours): cell death (complete inactivation) or returning
 Inactivation of membrane ATPase (Hoover et al., 1989) of the cell to its initial viable state due to pore resealing.
[23]
. In the latter case, the damage to the cell induced by the
 Nucleic acid and ribosomal disruption involved in protein pulsed electric field is sub-lethal.
synthesis.
The final result of the PEF treatment depends on the processes
Pulsed electric field going on during all these stages. During the action of an
In recent years, pulsed electric field as an emerging electric field, more and more cells become electroporated
technology has got wide interest for pasteurization of heat- (initial stage of pore formation) and the number of pores
sensitive liquid food (Mathys et al., 2013) [34], and for refining and/or their size increase. After an electric pulse, two
heat and mass transfer operations in the food industry competing processes proceed: (i) cells return to their former
(Puértolas et al., 2016) [49]. PEF provokes the formation of viable state due to pore resealing or (ii) cells die due to the
pores (electroporation phenomenon) by exposing the tissues loss of cell membrane integrity and intracellular compounds.
to an electric field for short high voltage pulses in the range of
10-80 KV/cm, resulting in cell membrane permeabilization. Applications of PEF in food processing
Electroporation may be either reversible or irreversible based Pulsed electric fields technology has been successfully used
on the optimization of electric field strength and treatment for the pasteurization of liquid and semisolid foods such as
intensity (Zimmermann, 1986) [57]. In case of reversible juices, milk, yogurt, soups, and liquid eggs. Application of
electroporation, transient pores formed enables entrapment of PEF processing is limited to food products with no air bubbles
materials of interest inside the cell membranes while and with low electrical conductivity. The maximum particle
Irreversible electroporation destroys the cells by permanent size in the liquid must be smaller than the gap of the treatment
membrane damage and is usually used in the processes of region in the PEF chamber in order to ensure proper
microbial inactivation and to increase extraction yield (Dukić- treatment. The effect of PEF at low electric fields applied
Vuković et al., 2017) [14]. This novel technology can ensure individually or in combination with heating has been
good product quality due to its non-thermal nature and low investigated in order to improve the extraction yield of
energy consumption. PEF is instant targeted, flexible, energy intracellular compounds present in fruits and vegetables
efficient and because heat is minimized products have longer (Donsì et al., 2010) [13]. PEF treatments at 0.1-10 kV/cm
shelf life whilst maintain better nutritional value than the increased the extraction of hydrophilic compounds, such as
conventional thermal processing. However PEF technology sugar from sugar beet (Eshtiaghi & Knorr, 2002) [15], betaine
does have some limitations. For example, any bacterial spores from red beetroot (López et al., 2009) [32] and anthocyanins
or mould ascospores in food products are usually resistant to from grapes, red cabbage (Gachovska et al., 2010) [17] or
PEF treatment, even at high intensity. This property could purple fleshed potatoes (Puértolas et al, 2013) [48]. PEF has
lead to a failure of the pasteurization process, resulting in a been recently introduced as an alternative pre-maceration
potential food safety hazard (Arroyo et al., 2012) [1]. In treatment to increase and speed-up polyphenolic extraction
addition to the spores or ascospores, enzymes are resistant to without altering the sensory properties, highlighting
PEF treatment. PEF processing is restricted to foods with no effectiveness in improving wine stability and color quality
air bubbles and with low electrical conductivity. If bubbles (Morata et al., 2017) [38].
are present in the PEF treatment chamber, dielectric
breakdown will occur.

Schematic drawing of a flow through treatment chamber

Stages of microbial inactivation process Electropermeabilisation of cells after expose to electric field
The process of microorganism inactivation can be divided and application in food and waste water processing with
into the following main stages typical electric field strength and energy input requirements.
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Cold plasma surface of bacterial cell also disrupts the membrane lipids.
Amongst all innovative non-thermal technologies, cold (Surowsky et al. 2013) [53] found that the active species in
plasma (CP) is a relatively novel technology emerged as an plasma react with the amino-acid in proteins which further
alternative source for surface sterilization and disinfection, for causes irreversible structural changes in proteins leading to
ensuring the quality and safety of minimally processed food the destruction of the microbial spores.
and the novelty lies with its non-thermal, economical,
versatile and environmentally friendly nature. The term L + OH• L• + H2O (1)
‘plasma’ refers to a quasi-neutral ionized gas, primarily L• + O2 L-OO• (2)
composed of electrons, ions and reactive neutral species in L-OO• + L L• + L-OOH (3)
their fundamental or excited states (Pankaj et al., 2014) [43]. L-OOH L-O• (4)
Based on the thermal equilibrium, there are two plasma
classes—denominated non-thermal plasma (NTP) or cold During application of plasma, microorganisms are exposed to
plasma and thermal plasma. Cold plasma is generated at 30- an intense radicals bombardment most likely provoking
60 °C under atmospheric or reduced pressure (vacuum), surface lesions that the living cell cannot repair quickly, this
requires less power, exhibits electron temperatures much process is termed “etching”. The phenomenon of etching is
higher than the corresponding gas (macroscopic temperature), based on the interaction of relative energetic ions and
and does not present a local thermodynamic equilibrium. The activated species with the molecules of the substrate. The
cold plasma technique was originally applied to enhance the accumulation of charges imparts an electrostatic force at the
antimicrobial activity in surface engineering, bio-medical outer surface of cell membranes which can cause cell wall
field and polymer industries (Sarangapani et al., 2015) [51]. rupture called as electropermeabilization as the same principle
Due to its excellent antimicrobial ability, cold plasma has occurring in pulsed electric fields. During application of
attracted much attention for non-thermal preservation of plasma treatment where plasma initiates, catalyzes, or helps
agricultural products, which has been studied for several fresh sustain a complex biological response, compromised
vegetables and fruits in recent years (Misra et al., 2014) [37]. It membrane structure (e.g. peroxidation) or change in
is suitable for treatment of heat-sensitive food products membrane bound proteins and/or enzymes leads to complex
because the ions and uncharged molecules gain only a little cell responses and may affect many cells as the affected cell
energy and remain at a low temperature (Pankaj et al., 2018) signal others.
[45]
.
Applications of cold plasma (CP)
Effect of Plasma on Microbial Cells In the past cold plasma was used for sterilization of thermo
The effect of plasma on microbial cells is cause of plasma labile materials in the biomedical technology sector and now
ions and cell interactions. The reactive species in plasma is it is extended to food industries as a novel non-thermal
widely accompanied with the direct oxidative effects on the technology. In food industry particularly, current cold plasma
outer surface of microbial cells. The plasma effect depends research are focused on its applications for food
highly on the presence of water, moist the organism highest decontamination, enzyme inactivation, toxin degradation,
the effect and vice versa (Dobrynin et al., 2009) [11] Microbial waste water treatment and packaging modifications.
inactivation of plasma is actually based on the fact that Specifically for food processing, cold plasma has proven to be
plasma reactive species damage the deoxyribonucleic acid effective for inactivation of food-borne pathogens and
(DNA) in the chromosomes. The ROS of interest in plasma spoilage microorganisms. Recently, (Han, et al. 2016)
processing are hydroxyl radicals, hydrogen peroxide, and the reported different inactivation mechanisms for Gram positive
superoxide anion (Wiseman and Halliwell, 1996) [55]. The and Gram negative bacteria by cold plasma. They observed
application of plasma for microbial inactivation results in that cold plasma inactivation of Gram positive bacteria
formation of malondialdehyde (MDA) in microbial cells, (Staphylococcus aureus) was mainly due to intracellular
which in turn participates in the formation of DNA adducts damage and little envelope damage whereas Gram negative
resulting in cell damage (Dobrynin et al., 2009) [11]. In bacteria (Escherichia coli) was inactivated mainly by cell
particular, reactive species interacts with water, leading to the leakage and low-level DNA damage. Apart from microbial
formation of OH* ions (Zou et al., 2003) [58] which are most inactivation, effects of cold plasma on the food quality has
reactive and harmful to the cells. It is worth mentioning that been another important aspect gaining attention of food
the OH* radicals formed in the hydration layer around the researchers. The changes in the enzymatic activity of trypsin
DNA molecule are responsible for 90 % of DNA damage. after the application of cold plasma was studied by (Dobrynin
Hydroxyl radicals can then react with nearby organics leading et al., 2009) [11]. It was reported that the plasma was able to
to chain oxidation and thus leads to destruction of DNA change the 3D structure of proteins in trypsin enzymes due to
molecules as well as cellular membranes and other cell cleavage of peptides bonds. In past few years cold plasma has
components (Dobrynin et al., 2009) [11]. Although it is well shown significant potential for degradation of various food
documented that reactive oxygen species such as oxygen toxins especially mycotoxins (Bosch et al., 2017) [8] drawing
radicals can produce profound effects on cells by reacting increased interest from food researchers. In case of the
with various macromolecules. The microorganisms are more packaging materials plasma treatment is used for surface
sensitive to singlet state oxygen leading to destruction of cells decontamination (Pankaj et al., 2016) [44], surface sterilization
(Aziz et al., 2014) [2]. On the other hand lipid bi-layer of (Vesel and Mozetic, 2012) [54] and surface treatments such as
microbial cell is more susceptible to atomic oxygen as the cleaning, coating, printing, painting, and adhesive bonding.
reactivity of atomic oxygen is much higher than the molecular The immobilization of bioactive functional compounds like
oxygen leading to the degradation of lipids, proteins and DNA lysozyme, nisin, vanillin, sodium benzoate, glucose oxidase,
of cells. The damage of the double bonds in lipid bi-layer bovine lactoferrin, lactoferricin, chitosan, nanosilver,
cause impaired movement of molecules in and out of cell. The trichlosan, or antimicrobial peptides into the packaging
bombardment of reactive oxygen species (ROS) on the material by plasma treatment has been extensively studied
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within the emerging field of antimicrobial and active Novel hydrodynamic cavitation application in food
packaging (Pankaj et al., 2014) [43]. Phsicochemical effects of industry
plasma generates the formation of oxidizing species: radicals Hydrodynamic cavitation phenomenon is of great significance
(H*, O*, OH*) may diffuse into the liquids and molecules in food extraction and processing. Various high-acid (pH ≥
(H2O2, O3, etc.), shockwave, ultraviolet light and 4.6) fluid foods have been processed in a hydrodynamic
electrohydraulic cavitation may degrade the pollutant in waste cavitation reactor for commercial sterility. The mechanisms
water or decomposes the pollutant into other compound (Jiang responsible for cellular inactivation are the physical stresses
et al., 2013) [25]. owing to hydrodynamic cavitation, and hence hydrodynamic
cavitation reactors can be readily applied for food
Hydrodynamic cavitation sterilization. (Milly et al. 2007) have investigated the
Hydrodynamic cavitation is another non-thermal application of hydrodynamic cavitation reactor for
underexplored technology in food processing (Gogate, 2011) sterilization of fluid foods such as tomato juice, apple juice
[19]
. It is considered more physically effective and energy and skim milk. It was reported that hydrodynamic cavitation
efficient than the ultrasound treatment. Hydrodynamic induced adequate destructive forces to inactivate vegetative
cavitation can simply be produced either by mechanical cells of bacteria, yeast, yeast ascospores and heat-resistant
rotation of an object through a liquid or by the passage of bacterial spores. The main advantage of using a
fluid through a constriction such as a venturi, an orifice plate hydrodynamic cavitation reactor can be lower operating
or a convergent divergent nozzle resulting in increase in temperatures for sterilization, and hence foods such as acidic
velocity at the expense of local pressure (Huang et al., 2013). fruit juices, salad dressings and milk can be safely processed
Because of constriction enormous gas bubbles are created and at reduced processing temperatures, resulting into superior
subsequently collapse violently downstream due to the product quality. Recently, (Milly et al., 2008) also
recovery of pressure, forming strong mechanical waves and investigated the application of shock wave reactor for
high-speed micro jets (Kuldeep et al., 2016). Collapsing inactivation of Saccharomyces cerevisiae in apple juice.
cavities generate highly reactive hydroxyl radicals which can With these few examples with actual fluid foods, it indeed
then be harnessed for a variety of applications. Cavitation appears that utilizing hydrodynamic cavitation as a processing
number (Cv), a dimensionless parameter, relates the flow technology allows processors to minimally heat treat fluid
conditions with the cavitation intensity. Ideally, cavitation is foods while extending shelf life of perishable products such as
generated when Cv is between 0.1-1, obtained by adjusting apple juice. Reducing thermal treatments and thus retaining
the flow condition and reactor geometry (Bagal and Gogate, heat labile nutrients and flavor components by processing
2014) [3]. This novel technology offers several advantages with hydrodynamic cavitation creates superior products in
such as no additional chemicals (clean tech), compact and in- today's market where “fresh picked” flavours and
line reactors and low costs making it a promising technology healthy/nutritious products drive consumption trends. Apart
platform. from food industry, hydrodynamic cavitation has found wide
applications in the field of microbial cell disruption
Principle (Balasundaram and Pandit, 2001), water disinfection (Chand
Novel hydrodynamic cavitation basically describes the et al., 2007), wastewater treatment (Pradhan and Gogate.,
process of vaporization, bubble generation and bubble 2010) [47] and sludge decomposition (Hirooka et al., 2009) [22].
implosion. Cavitation occurs when local pressure drops below
saturated vapour pressure and recovers above vapour Concluding remarks
pressure, as a result of sudden decrease and increase in local Trends in the emergence of novel non-thermal processing
pressure. Flashing is said to have occurred if the recovery technology with improved quality and safety resulted in
pressure is not above the vapour pressure. Increase in kinetic innovations in processing techniques. Research and
energy or an increase in the pipe elevation is responsible for development in response to consumer preferences gave rise to
the generation of cavities in the pipe systems. HPP, PEF, cold plasma (CP) and hydrodynamic cavitation
Cavitation is damaging when uncontrolled. Cavitation power (HC) food processing techniques that are purely innovative.
can be harnessed and non destructive by controlling the flow These innovative processsing technologies contributed toward
of the cavitation. Controlled cavitation generates free radicals the enhancement of food quality, safety, feasibility and
due to disassociation of vapors trapped in the cavitating bioactivity of functional components. Applicability of novel
bubbles. It can be used to enhance chemical reactions or and innovative processing techniques is growing widely
propagate certain unexpected reactions which can lead to because of their health impact and thus resulted in reduced
degradation or even mineralisation of water constituents consumer complaints. In the near future traditional thermal
without addition of any chemicals. Extent of cavitation taking processing will be completely replaced by innovative food
place in any system is explained in terms of the cavitation processing techniques as these techniques are rapidly making
number and is simply derived from Bernoulli’s theorem their way into the global market.
expressed by the following equation:
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