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<p>The growing demand for minimally processed, safe, and nutritionally superior foods has accelerated the adoption of non-thermal food processing technologies. While these technologies effectively inactivate spoilage and pathogenic microorganisms with minimal heat damage, their successful industrial implementation requires precise, process-specific, and real-time monitoring and control systems to ensure consistent food quality and safety. This review comprehensively examines recent advances in non-thermal food processing techniques with the integration of physical, chemical, optical, spectroscopic, and biological sensor systems for real-time process monitoring and control. Particular emphasis is placed on sensor-based approaches including temperature, pressure, flow, acoustic, electrical, chemical, optical, spectroscopic, and biosensor technologies that enable non-destructive, inline or online assessment of key quality attributes such as microbial inactivation, physicochemical stability, oxidation status, and structural integrity. The role of advanced spectroscopic tools such as near-infrared spectroscopy, Raman spectroscopy, fluorescence techniques, and hyperspectral imaging, in evaluating biochemical changes during non-thermal treatments is highlighted. Furthermore, emerging trends involving nano-biosensors, artificial intelligence, machine learning, big data analytics, and Internet of Things (IoT)-enabled platforms are discussed as critical enablers of intelligent, Industry 4.0 driven, closed-loop control systems. Overall, this review underscores the synergistic potential of combining non-thermal processing technologies with advanced sensor integration to enhance food safety, quality consistency, sustainability, and process efficiency in next generation food manufacturing systems.</p>

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Advances in non-thermal processing techniques and sensor-integration: real-time monitoring and control for food quality and safety

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • Gaveshani Kavindya,
  • Pavithra Alahakoon,
  • Thilini Ranasinghe,
  • Dimuthu Chandrasekara,
  • Anupama Herath,
  • Pramod Bandara

摘要

The growing demand for minimally processed, safe, and nutritionally superior foods has accelerated the adoption of non-thermal food processing technologies. While these technologies effectively inactivate spoilage and pathogenic microorganisms with minimal heat damage, their successful industrial implementation requires precise, process-specific, and real-time monitoring and control systems to ensure consistent food quality and safety. This review comprehensively examines recent advances in non-thermal food processing techniques with the integration of physical, chemical, optical, spectroscopic, and biological sensor systems for real-time process monitoring and control. Particular emphasis is placed on sensor-based approaches including temperature, pressure, flow, acoustic, electrical, chemical, optical, spectroscopic, and biosensor technologies that enable non-destructive, inline or online assessment of key quality attributes such as microbial inactivation, physicochemical stability, oxidation status, and structural integrity. The role of advanced spectroscopic tools such as near-infrared spectroscopy, Raman spectroscopy, fluorescence techniques, and hyperspectral imaging, in evaluating biochemical changes during non-thermal treatments is highlighted. Furthermore, emerging trends involving nano-biosensors, artificial intelligence, machine learning, big data analytics, and Internet of Things (IoT)-enabled platforms are discussed as critical enablers of intelligent, Industry 4.0 driven, closed-loop control systems. Overall, this review underscores the synergistic potential of combining non-thermal processing technologies with advanced sensor integration to enhance food safety, quality consistency, sustainability, and process efficiency in next generation food manufacturing systems.