Nonthermal Technologies in Plant-Based Alternative Processing: Applications, Challenges, and Future Perspectives

The growing demand for plant-based alternatives has urged the development of advanced processing technologies that enhance product quality while maintaining nutritional integrity. Nonthermal technologies, including high-pressure processing (HPP), pulsed electric field (PEF), ultrasound, ultraviolet (UV) light, irradiation, and cold plasma (CP), offer effective alternatives to traditional thermal methods. These technologies improve microbial safety, enhance protein functionality, and extend shelf life without compromising sensory and nutritional properties. This review summarizes the applications of nonthermal technologies in plant-based food processing, focusing on their roles in modifying texture, flavor, protein structure, and nutrient bioavailability. HPP enhances food safety and textural properties, while PEF facilitates protein extraction and enzymatic modifications. Ultrasound aids in emulsification and structural changes, whereas UV light and irradiation contribute to microbial decontamination and shelf life extension. CP shows potential in antimicrobial applications and as an enhancer of functional ingredients. Despite their advantages, challenges such as scalability, processing costs, regulatory concerns, and consumer acceptance hinder widespread adoption. Moreover, the complex interactions between plant-based matrices and nonthermal treatments require further investigation to optimize processing conditions. Future research should investigate the synergistic effects of combining multiple nonthermal techniques, enhance process efficiency, and establish standardized guidelines for industrial applications. Advances in automation and real-time monitoring could further enhance these technologies, ensuring the production of high-quality, sustainable, and nutritionally optimized plant-based alternatives. With continued innovation, nonthermal processing has the potential to revolutionize the plant-based food industry.