Current physical processing technologies for salt reduction in prepared dishes

Abstract

The increasing popularity of prepared dishes, attributed to their diverse flavors, safety (absence of preservatives), and cooking convenience, is marred by high salt content, posing significant health risks. Traditional salt reduction methods often compromise food quality, incur high costs, possible toxicity and pose scalability and safety challenges. This review explores current physical processing technologies (PPTs), including ultrasound (US), pulsed electric fields (PEF), high pressure processing (HPP), microwave (MW), radio frequency (RF) and others, as promising alternatives for reducing salt in prepared dishes. These technologies are characterized by their eco-friendliness, efficiency, intelligence, and structural modification capabilities. We provide an in-depth analysis of the challenges associated with salt reduction, focusing on flavor, texture, safety, color, and other considerations. The review categorizes the preparation process into four critical stages: raw material pre-processing, pre-cooking, storage, and thawing, examining the applications and potential mechanisms of PPTs at each stage. For instance, in pre-processing, US-assisted curing increased salt diffusion by 30–50 % in muscle foods through cavitation and sponge effects, while HPP enhanced Na⁺ redistribution via protein unfolding and ionic binding. Furthermore, the review outlines current limitations—such as equipment complexity, parameter sensitivity, and regulatory gaps—and explores future prospects for PPTs in low-salt prepared dish production. By integrating mechanistic insights with stage-specific applications, this work provides both a theoretical basis and practical guidance for the development and industrial adoption of low-salt prepared dishes.