Non-thermal processing encompasses a range of emerging food technologies, including high-pressure processing (HPP), pulsed electric field (PEF), cold atmospheric plasma (CAP), high-pressure carbon dioxide (HPCD), and ultrasound (US). Unlike traditional thermal processing or chemical preservatives, these methods offer advantages such as lower energy consumption, enhanced environmental sustainability, and effective microbial inactivation, thereby extending food shelf life. Moreover, they can better preserve the nutritional integrity, color, flavor, and texture of food products. However, a critical concern associated with non-thermal processing is its potential to induce microorganisms into a viable but nonculturable (VBNC) state. These VBNC cells evade detection via conventional culturing techniques and may remain metabolically active and retain virulence, posing hidden food safety risks. Despite these implications, comprehensive reviews addressing the induction of a VBNC state by non-thermal treatments remain limited. This review systematically summarizes the microbial inactivation effects and mechanisms of non-thermal processing techniques, the VBNC state, and their associated hazards. This review aims to support technological innovation and sustainable advancement in non-thermal food processing.
Keywords: hazardous risks; microbial inactivation; non-thermal processing; viable but nonculturable state.