The underestimated factors affecting biofilm formation and microbial food safety in dairy processing environments

Background Bacterial biofilms are a persistent and mechanistically complex source of contamination in dairy processing environments, posing serious food safety risks due to their protection of pathogens and resistance to conventional sanitation methods. Aim(s) This review aimed to examine the influence of dairy composition and processing conditions on biofilm formation, extending previous composition‐focussed analyses by integrating microbial interactions, surface conditioning effects and the often insufficiently integrated role of commensal bacteria in biofilm persistence and pathogen protection. Methods A comprehensive synthesis of peer‐reviewed literature was conducted through systematic searches of Scopus, Web of Science, PubMed and Google Scholar, focussing on biofilm formation in dairy systems, dairy matrix effects, microbial interactions and sanitation strategies. Major Findings The nutrient‐rich composition of dairy products (proteins, fats, lactose and minerals) contributes to biofilm development by enhancing microbial adhesion and extracellular polymeric substance (EPS) production, although the role of individual components, particularly lactose, is highly species‐ and context‐dependent. Processing conditions (moisture levels, temperature and fluid dynamics) and surface properties (material, roughness and hydrophobicity) further influence biofilm dynamics. Commensal bacteria, increasingly recognised as active contributors to biofilm ecology, participate in biofilm stabilisation, facilitate pathogen survival and exhibit resistance to sanitisers. Advances in detection methods, including molecular and imaging tools, have improved biofilm monitoring. Integrated control strategies, such as enzymatic cleaners, bacteriophages, nonthermal technologies, hygienic design and staff training, are essential for effective biofilm management. Scientific or Industrial Implications The findings underscore the need for a multidisciplinary approach combining microbiology, food engineering and industrial practice to mitigate biofilm‐related risks. This review provides actionable insights for dairy processors to enhance biofilm detection, control and prevention, thereby supporting global food safety standards and improving product quality across the supply chain.